Powder Bed Fusion Technique Research Articles

Heat treatments effects on Wear performance of Laser based Powder Bed Fusion fabricated Inconel 718 alloy

Among the AM processes Laser based Powder Bed Fusion (LPBF) technique offers precise and complex geometric fabrication. However, the microstructural and mechanical properties obtained from LPBF process requires further investigation, especially for IN718 superalloys. In this study, various heat treatments were applied to LPBFed Inconel 718 specimens to examine their effects on microstructure, microhardness and wear behavior. Three different heat treatments, each involving varied solutionizing and ageing steps were incorporated. As-printed specimens exhibited distinct fish scale structures with columnar dendrites. Heat treatments effectively dissolved the Laves phase and precipitated strengthening phases like γ′′ and γ′. Microhardness increased significantly after heat treatments, correlating with the formation of strengthening precipitates. Friction and wear tests showed as-printed specimens exhibited higher wear loss (922 ± 13 μm) and coefficient of friction (COF) (0.511 ± 0.07) due to the presence of Laves phase and softer matrix. Heat-treated specimens demonstrated significantly reduced wear loss (262 ± 5 μm) and COF (0.368 ± 0.01), with HT2 showing the best wear resistance attributed to a homogeneous microstructure. SEM analysis of worn surfaces confirmed abrasive and adhesive wear mechanisms in as-printed specimens, while heat-treated specimens exhibited reduced wear with smoother surfaces.

High-temperature fracture behavior of an α/β Titanium alloy manufactured using laser powder bed fusion

The room and high temperature (up to 600 °C) mechanical properties, with emphasis on the fracture toughness and fatigue resistance, of an α/β titanium alloy that was additively manufactured using the laser powder bed fusion (LPBF) technique were evaluated in the as-printed (α’ lath martensite with negligible β phase content) and heat-treated (α/β structure with a significant volume fraction of the β phase) states for critically examining the β phase's role in the fracture and fatigue behavior (given the significantly higher diffusion rates of various species in β compared to α). Experimental results reveal that the heat-treated sample exhibits superior ductility and fracture initiation toughness at elevated temperatures, compared to the as-printed sample, due to the presence of β ligaments in the former. They also prevent strain localization along the prior β grain boundaries, and their absence in the as-printed state leads to cracking along those boundaries. While the fatigue crack growth (FCG) rates in both the as-printed and heat-treated samples deteriorated with increasing temperature, the threshold for FCG generally increased, which is attributed to creep-induced crack tip blunting. Moreover, a double Paris exponent phenomenon is observed for the heat-treated sample at 300 °C, attributed to the hydrogen-assisted crack growth, with β phase providing an accelerated diffusion pathway. Overall, the experimental results and their analyses illustrate the intricate relationship between creep, hydrogen diffusion, and the β phase in dictating the fracture behavior of LPBF α/β titanium at elevated temperatures.

A Systematic Review on the Generation of Organic Structures through Additive Manufacturing Techniques.

Additive manufacturing (AM) has emerged as a transformative technology in the fabrication of intricate structures, offering unparalleled adaptability in crafting complex geometries. Particularly noteworthy is its burgeoning significance within the realm of medical prosthetics, owing to its capacity to seamlessly replicate anatomical forms utilizing biocompatible materials. Notably, the fabrication of porous architectures stands as a cornerstone in orthopaedic prosthetic development and bone tissue engineering. Porous constructs crafted via AM exhibit meticulously adjustable pore dimensions, shapes, and porosity levels, thus rendering AM indispensable in their production. This systematic review ventures to furnish a comprehensive examination of extant research endeavours centred on the generation of porous scaffolds through additive manufacturing modalities. Its primary aim is to delineate variances among distinct techniques, materials, and structural typologies employed, with the overarching objective of scrutinizing the cutting-edge methodologies in engineering self-supported stochastic printable porous frameworks via AM, specifically for bone scaffold fabrication. Findings show that most of the structures analysed correspond to lattice structures. However, there is a strong tendency to use organic structures generated by mathematical models and printed using powder bed fusion techniques. However, no work has been found that proposes a self-supporting design for organic structures.

Superior passivation capability for biomedical-grade CoCrMo alloys fabricated by laser powder bed fusion with nitrogen doping

Nitrogen, a non-metallic element, is widely abundant in nature and possesses numerous advantageous properties for metals and alloys, and supersaturated nitrogen content can be obtained through non-equilibrium rapid solidification. In this work, the microstructure and passivation properties of CoCrMo alloys prepared by the laser powder bed fusion (LPBF) technique under nitrogen and argon atmospheres were compared through multi-scale microstructural characterization combined with advanced electrochemical testing methods. Results show that the N content in LPBF N2-CoCrMo alloy (0.1839 wt%) demonstrates more than one order of magnitude higher than that of LPBF Ar-CoCrMo counterparts (0.0046 wt%). Despite comparable sub-microstructures in grain structure and dislocation cells, the LPBF N2-CoCrMo alloy demonstrates a higher corrosion potential of −0.34 VSCE and lower corrosion current density in comparison to the LPBF Ar-CoCrMo in a chloride-containing solution. Moreover, the passive film of LPBF N2-CoCrMo alloys shows a low defect density with a high-content and dense Cr2O3 layer therein. Our research calls attention to alloy design enhancement by modifying protective atmospheres during the additive manufacturing process.

Improved properties of additively prepared Inconel 718 alloy post-processed with a new heat treatment

In this study, an alternative heat-treatment route has been explored to optimize the mechanical as well as the fatigue properties of Ni-based 718 alloy fabricated using additive methods. The test coupons were prepared using the laser-based powder bed fusion technique and post-processed with a new heat-treatment condition (NHT): solution treatment at 1130°C for 2hr followed by water cooling (WC) and the artificial aging at 730°C for 13hr followed by furnace cooling (FC). It was found that the NHT parameters enhanced the mechanical properties as well as the fatigue properties as compared to the standard heat-treatment (SHT) conditions: solution treatment at 980°C-1hr-FC followed by two-step artificial aging 720°C-8hr-FC(55°C/hr up to 620°C) + 620°C-8hr-FC. The NHT condition resulted in a more homogenized and recrystallized microstructure with a higher volume fraction of γ′ and γ′′ precipitates, high-angle coincidence site lattice (CSL) as well as the twin boundaries and marginally reduced grain size. The microhardness, tensile strength, and fatigue strength after the NHT condition were improved by ∼15%, ∼16%, and ∼12.5%, respectively, and it was mainly accredited to the high volume fraction of fine strengthening precipitates and homogenized microstructure.

Toward additive manufactured crack-free NiTiCu shape memory alloys with low-hysteresis and tailorable phase transition behavior supported by theoretical design

In this study, a novel NiTiCu alloy composition (i.e., Ni41.5Ti49.5Cu9.0 in at%) with low hysteresis and two-step martensitic transformation was first designed for laser powder bed fusion (LPBF) technique through a combination of CALPHAD and machine learning techniques. The LPBF-fabricated NiTiCu alloy displayed a cellular grain structure devoid of discernible cracks. Following solution and aging treatments, the NiTiCu samples exhibited the desired two-step martensitic transformation with a low thermal hysteresis of 8.9 K, aligning closely with the design specifications. Interestingly, the heat-treated samples demonstrated enduring stability in recovery strain, achieving a remarkable 5.76 % over the course of 50 cyclic loading tests. Fundamentally, the sustained recovery strain observed and the nuanced variations in superelastic behaviors can be ascribed to the interaction between dislocations and Ti2(Ni, Cu)/Ni4Ti3 precipitates. The saturation of dislocations around precipitates stabilized the partial martensite and hindered the slip deformation, thereby ensuring stable superelastic behavior. Finally, an effective roadmap toward crack-free LPBF-fabricated NiTiCu shape memory alloys with desired phase transition behavior was proposed. It is envisaged that such a roadmap holds promise for broader applicability across other NiTi-based shape memory alloys.

Regulating precipitation behavior in an ultrahigh-strength, high-molybdenum maraging steel via laser powder bed fusion

In high-molybdenum (Mo) maraging steels, the formation of coarse Mo-enriched precipitates during conventional hot processing can significantly compromise both strength and ductility. In this contribution, we utilized the laser powder bed fusion (L-PBF) technique to produce a high-Mo maraging steel with a nominal chemical composition of Fe-13Ni-12Co-10Mo-1W-1Ti (wt.%). Notably, the ultrafast cooling rate inherent to L-PBF successfully suppresses the formation of coarse Mo-enriched precipitates. The co-precipitation of high-density Ni3Ti and Mo-enriched nanoprecipitates within the direct-aged martensitic matrix was observed. As a result, despite containing ∼16% soft reverted austenite, the direct-aged samples exhibit an ultrahigh yield strength (YS) of ∼ 2.34 GPa and an ultrahigh ultimate tensile strength (UTS) of ∼2.57 GPa, with an acceptable uniform elongation (UE) of around 2.7%. This work may provide a new pathway for the development of ultrahigh-strength maraging steels.

Effect of heat treatment on the microstructure and properties of CuCrZr prepared by laser powder bed fusion

In this paper, CuCrZr alloys were prepared by laser powder bed fusion technique. Under optimum forming process conditions, a relative density of 99.7% was obtained and the specimens were analyzed for microstructure and properties. To enhance the mechanical properties of the copper alloy, the specimens are post-treated using both solution aging and direct aging heat treatments. The variation and influence mechanism of microstructure and mechanical properties, thermal conductivity and electrical conductivity were studied and analyzed. With direct aging heat treatment a large number of Cr nanoprecipitates can be obtained, significantly improving the properties of the alloy. The best synthesis properties obtained at an aging temperature of 450 °C were: microhardness 168.7 ± 3.1 HV, ultimate tensile strength 481.7 ± 7.6 MPa, electrical conductivity 73.9 ± 0.9 %IACS, thermal conductivity 314.3 ± 5.3 W/(m·K).

Electron beam powder bed fusion of Ti-30Ta high-temperature shape memory alloy: microstructure and phase transformation behaviour

ABSTRACT The present study reports on additive manufacturing of a Ti-30Ta (at.%) high-temperature shape memory alloy (HT-SMA) using electron beam powder bed fusion (PBF-EB/M) technique. Detailed microstructure analysis was conducted to reveal the microstructural evolution along the entire process chain, i.e. from gas-atomised powder to post-processed material. PBF-EB/M processed structures with near full density and an isotropic, β-phase stabilised microstructure, i.e. equiaxed β-grains of around 20 µm in diameter with no preferred crystallographic orientation, are reported. As revealed by differential scanning calorimetry, post-process heat-treated Ti-Ta demonstrates a reversible martensitic phase transformation well above 100°C. Although partly unmolten Ta-particles after both gas atomisation and PBF-EB/M remain a challenge towards robust processing, PBF-EB/M appears to show significant potential for fabrication of Ti-Ta HT-SMAs, especially when functional metal parts and components with complex shapes are required, which are difficult to fabricate conventionally.

Influence of raster orientation on fracture behavior of Ti6Al4V alloy manufactured by Laser powder bed fusion

This study analyzes the fracture characteristics of Ti6Al4V alloy manufacturedby the Laser Powder Bed Fusion (LPBF) technique, specifically investigating the effect of raster orientation. A modified yield function is presented to determine the decrease in load-carrying ability attributed to shear effects. The damage variable includes both the void volume fraction and shear damage variables, taking into consideration the consequences of void interaction. The research utilizes Finite Element Analysis (FEA) together with calibrated modified GTN fracture parameters derived from Hill’s 48 parameters to accurately predict material behavior. Uniaxial tension tests are carried out on samples in different raster orientations:0°, 45°, and 90°. The Scanning Electron Microscope (SEM) is used to conduct a more thorough examination of the fracture’s characteristics. The specimens with a 90° raster orientation exhibit considerable plastic deformation with deepdimples on the fractured surface, along with irregularly shaped voids. In contrast, the sections with 45° and 0° orientations display smaller dimples and smoother cup and cone features without significant plastic deformation. The results demonstrate that the direction of the raster has a considerable impact on the plastic modulus and fracture properties of the material.

Exploring Elemental Powder Approach for Making Al and Ti Containing High-Entropy Alloys by Powder Bed Fusion

This research aimed to produce high-entropy alloys (HEA), namely Mn–Fe–Co–Ni + 5Al and Mn–Fe–Co–Ni + 5Al + 5Ti, through the Powder Bed Fusion technique using elemental powders. Alloy composition has been selected to achieve a HEA matrix with strengthening intermetallic precipitates. Thermo-Calc software has been used to predict solidification behavior and phase stability for non-equilibrium conditions. The experiment involved the execution of an additive manufacturing process with a laser working in point-by-point exposure mode to produce samples using varying laser power and exposure time. The samples underwent investigation via macroscopic examination, porosity analysis, scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction, and hardness testing. Results have shown that processing parameters and alloy constituents directly influenced processability and sample traits. What is more, a high-energy laser beam introduction to the material during the process has helped mitigate the formation of large Ti or Al oxides. In addition, EDS analysis indicated that higher Volumetric Energy Density values enhanced the uniformity of chemical composition, indicating that homogeneity can be achieved by selecting appropriate melting parameters. The results clearly show that these alloys can be successfully (by means of porosity and homogeneity) manufactured from elemental powders via the powder bed fusion technique.

Effects of the unit-cell size and arrangement on the compressive behaviors of lattice structures in powder bed fusion additive manufacturing

Lattice structures demonstrate a unique compressive behavior wherein the compressive strength increases and converges to a specific value as the number of unit-cell arrangements and overall dimensions of the lattice structure increase. In this study, the effects of the unit-cell size and cell arrangement on the compressive behavior of lattice structures were investigated to determine the convergence of compression characteristics at specific unit-cell configurations. Simple cubic lattice structures were designed and manufactured using powder bed fusion techniques. The lattice structures were characterized using universal testing machines. Experimental results revealed that the convergence of compressive strength was influenced by the size of the unit cell: the number of arrangements at which a specific compressive strength was reached increased as the unit-cell sizes decreased. Furthermore, specific convergence points were determined for different unit-cell sizes, providing valuable insights into the compressive strength behavior of lattice structures. This study emphasizes the significance of considering both unit-cell arrangements and overall dimensions when designing standard specimens for compression testing. Additionally, the methodology developed in this study can be applied to obtain an optimal configuration for desired strength characteristics.

Nanostructuring of an additively manufactured CoCrFeNi multi-principal element alloy using severe plastic deformation: Comparison of two materials processed by different laser scan speeds

Experiments were conducted to reveal the refinement of the microstructure and the evolution of the hardness of an additively manufactured (AM) CoCrFeNi multi-principal element alloy (MPEA) processed by severe plastic deformation (SPD) using high pressure torsion (HPT) technique. AM was carried out by laser powder bed fusion (L-PBF) technique at two different laser scan speeds. The as-built alloys for both laser scan speeds have a single-phase face-centered cubic (fcc) structure with <110> fiber texture parallel to the building direction. X-ray line profile analysis (XLPA) revealed that the dislocation density was considerably high even in the AM-processed state before HPT (3 × 1014 m−2) which increased by two orders of magnitude during HPT. The saturation of the lattice defects (dislocation density and twin fault probability) as well as the crystallite size occurred at a shear strain of about 10 during HPT. In both AM-processed alloys, <111> fiber texture developed parallel to the normal of the HPT-processed disks. For both laser scan speeds, the initial grain size in the AM-processed samples was refined from 70 to 90 μm to the nanocrystalline regime after 10 turns of HPT. Additionally, nanotwins formed with a probability of about 3 %. The initial hardness of the AM-processed MPEA samples for both laser scan speeds was 2700–2800 MPa, which is superior to that of CoCrFeNi produced by casting (about 1380 MPa). This can be explained by the high dislocation density in the AM-processed specimens. The formation of nanostructure with high lattice defect density during HPT resulted in a very high hardness value of about 5500 MPa in the AM-processed CoCrFeNi MPEA samples for both laser scan speeds.

Laser powder bed fusion of oxide dispersion-strengthened IN718 alloys: A complementary study on microstructure and mechanical properties

In this study, two new grades of oxide dispersion strengthened (ODS) Inconel 718 (IN718) alloys were designed by the thermochemical CALPHAD method and produced by laser powder bed fusion (LPBF) technique. Alloys designated as IN718-YF and IN718-YFH, that consist Y2O3–FeO and Y2O3–FeO–Hf, respectively, were fabricated with >99.9 % densification using optimized process parameters. CALPHAD calculations were highly consistent with experimental findings, highlighting the formation of Al-containing Y–Ti–O and Y–Hf–O nano-oxides in both alloy types. Texture analyzes revealed no significant texture development in as-built (AB) or heat-treated (HT) alloys. Heat treatment was applied at 1050 °C for 1 h to enhance nano-oxide density. The nano-oxide number density remained similar in IN718-YF while it decreased in IN718-YFH alloy as a result of carbide formation after the heat treatment. Besides, formation of secondary γ′ particles was observed in the IN718-YFH/HT alloy. Even though the yield strengths of IN718-YF and IN718-YFH alloys in both AB and HT conditions were similar, the ductility of IN718-YFH was ∼50 % less in almost all conditions compared to the ductility of IN718-YF. This has been shown to be as a result of irregular shaped micron-sized Y-Hf-O oxides, martensite formation in AB condition, increased amount of carbides and existence of secondary γ′ particles in HT condition in IN718-YFH. High density of stacking faults (SF) forming at the interface of the nano-oxides have been detected in IN718-YF alloys. Besides dislocation/nanoparticle interactions, SFs which are responsible for the delocalization of the deformation improve the ductility of IN718-YF alloys. Overall, high temperature mechanical tests exhibit that both alloys have higher strength with improved ductility compared to the standard IN718 alloys, indicating the contribution of the nano-oxides.

Microstructure-Based Modeling of Deformation and Damage Behavior of Extruded and Additively Manufactured 316L Stainless Steels.

In this study, we investigated the micromechanical deformation and damage behavior of commercially extruded and additively manufactured 316L stainless steels (AMed SS316L) by combining experimental examinations and crystal plasticity modeling. The AMed alloy was fabricated using the laser powder bed fusion (LPBF) technique with an orthogonal scanning strategy to control the directionality of the as-fabricated material. Optical microscopy and electron backscatter diffraction measurements revealed distinct grain morphologies and crystallographic textures in the two alloys. Uniaxial tensile test results suggested that the LPBFed alloy exhibited an increased yield strength, reduced elongation, and comparable ultimate tensile strength in comparison to those of the extruded alloy. A microstructure-based crystal plasticity model was developed to simulate the micromechanical deformation behavior of the alloys using representative volume elements based on realistic microstructures. A ductile fracture criterion based on the microscopically dissipated plastic energy on a slip system was adopted to predict the microscopic damage accumulation of the alloys during plastic deformation. The developed model could accurately predict the stress-strain behavior and evolution of the crystallographic textures in both the alloys. We reveal that the increased yield strength in the LPBFed alloy, compared to that in the extruded alloy, is attributed to the higher as-manufactured dislocation density and the cellular subgrain structure, resulting in a reduced elongation. The presence of annealing twins and favorable texture in the extruded alloy contributed to its excellent elongation, along with a higher hardening rate owing to twin-dislocation interactions during plastic deformation. Moreover, the grain morphology and defect state (e.g., dislocations and twins) in the initial state can significantly affect strain localization and damage accumulation in alloys.

Random Vibration Characteristics and Vibration Suppression of an Aero-engine Inlet Rake Fabricated by Laser Powder Bed Fusion

The inlet rake is generally installed in aero-engine during rig and flight test for flow field pressure and temperature measuring. There are usually complex flow channels and pipelines inside the rake to extract air flow to the sensor. The laser powder bed fusion(L-PBF) technique was applied in rake fabrication recently due to its progressive layer stacking molding procedure. However, the difference of thermoforming method between L-PBF and the traditional casting process leads to the mechanical property disparities of the material. In this work, the determinants of random vibration response of the inlet rake manufactured by L-PBF with GH4169 powder were studied individually. The stiffness and yield property of the material were investigated by the specimen tensile test, which indicates higher elasticity modulus and yield stress comparing to the ones by castling or forging process. The damping ratio of the inlet rake was obtained through stress attenuation characteristics experiment and analysis under stepwise excitation. The stress distribution and resonance margin of the inlet rake under the aero-engine random vibration spectrum were simulated by finite element modal and random vibration analysis. The results showed that the damping ratio of the L-PBF inlet rake is much smaller than engineering recommendations, and the resonance margin is insufficient. Thus, the stress level of the inlet rake was very high, especially in the blade root section, quite close to the yield limit of the material. To solve this problem, the vibration suppression methods of the inlet rake were studied from the perspective of structural design optimization and damping ratio increasing. Through the rational design of the resonance margin and addition of vibration damping structure, the vibration stress of inlet rake was significantly suppressed. As the result, the rake was installed in the inlet during the aero-engine rig test for flow field pressure and temperature measurement successfully.

Effect of design parameters on auxetic behavior and stiffness of additively manufactured 316L stainless steel

Auxetic structures, characterized by showing negative Poisson's ratio (ʋ) when loaded, are cellular metamaterials consisting of connected struts in repeating unit cells. The mechanical behavior of auxetics depends on dimensions of the unit cell such as height and length of the unit cell, strut thickness (St), and orientation angle (θ) of the struts. The present study investigates effects of variations in St and θ on ʋ and stiffness (E) of additively manufactured 316L stainless steel with re-entrant honeycomb auxetics fabricated by laser powder bed fusion technique. Poisson's ratio was acquired through linear elastic simulations via finite element analysis (FEA) and verified experimentally through digital image correlation (DIC) facility attached to tensile tests. The design of the auxetic patterns entailed a simulation of thirty-five distinct models, incorporating St values of 0.4–1.6 mm, as well as θ values of 70–90°. In comparison, experimental validation was conducted on nine specimens, featuring St values of 0.6–1.4 mm, and θ values of 70–80°. FEA and experimental results obtained by DIC exhibited ʋ values of −5.23 to −0.3 (for St 0.6-1.4 mm and θ 70–80°), displaying increased ʋ with reductions in both St and/or θ. Meanwhile, E increased with St increase or θ decrease, exhibiting values of 18.9–72 GPa, which could be optimized to fit with human bones stiffness as potential orthopedics implantation in future.

Nanometer-scale porosity evolution and mechanical properties of additively manufactured 17-4PH stainless steel

Understanding of the microstructure and mechanical properties of additively manufactured (AM) 17-4PH stainless steel has matured significantly, but combined wrought-level strength and ductility has yet to be achieved. Identifying the microstructural obstacle(s) impeding this milestone is critical for many future applications and industries interested in this AM alloy. In this work, microstructure, mechanical properties, and fracture behavior is evaluated for AM 17-4PH built via the laser powder bed fusion technique (LPBF) and heat treated via a broad range of techniques to achieve wrought-level 17-4PH strength. The highest strength/ductility was achieved with a two-stage hot isostatic press (HIP) and solution anneal (SA) treatment followed by an aging heat treatment, but wrought-level ductility could not be matched. Persistent nano-porosity (0.06–0.23 μm) was identified and correlated to fracture surface dimpling (R2 = 0.73–0.85) indicating a possible role in this ductility limitation. Contextualization of this study's mechanical properties dataset within the literature suggests that this observation is endemic to the current state-of-the-art processing techniques for AM 17-4PH.

Reducing part deformation of isotactic polypropylene specimens fabricated with powder bed fusion technique through controlling crystallization behaviors

AbstractSerious shrinkage and warpage are obstacles to the development of ideal isotactic polypropylene (iPP) materials for polymer‐based powder bed fusion (PBF) technique. In this work, the variations of the dimensional accuracy of the PBF‐printed iPP parts were investigated with various printing parameter and nucleating agent. The iPP parts printed at a scanning speed of 700 mm/s exhibit smaller extents of shrinkage and curling than those at lower speeds, due to a lower degree of crystallinity. Interestingly, iPP blended with the α‐ or β‐nucleating agent demonstrates more serious part deformation with respect to neat iPP. Especially, α‐nucleating agent tends to trigger the most severe curling under the investigated printing parameters. Based on X‐ray diffraction and differential scanning calorimetry (DSC) results, both neat iPP and α‐iPP parts crystallize into α‐crystal, while β‐iPP parts display the coexistence of β‐ and α‐crystals. And, the difference of the crystallinity is less than 3% in three specimens. This suggests that both crystallinity and crystalline structure are not the main reasons for the shrinkage and warpage in this case. Instead, the severe part deformation of the α‐iPP parts is assigned to the narrower sintering window as well as the higher onset crystallization temperature of α‐iPP, which hinder relaxation of residual stresses. This work provides insights into the part deformation mechanism for PBF‐processed polymer materials.

Multifactorial impacts of B-doping on Fe81Ga19 alloys prepared by laser-beam powder bed fusion: Microstructure, magnetostriction, and osteogenesis

Magnetostrictive Fe-Ga alloys have captivated substantial focus in biomedical applications because of their exceptional transition efficiency and favorable cytocompatibility. Nevertheless, Fe-Ga alloys always exhibit frustrating magnetostriction coefficients when presented in bulk dimensions. It is well-established that the magnetostrictive performance of Fe-Ga alloys is intimately linked to their phase and crystal structures. In this study, various concentrations of boron (B) were doped into Fe81Ga19 alloys via the laser-beam powder bed fusion (LPBF) technique to tailor the crystal and phase structures, thereby improving the magnetostrictive performance. The results revealed the capacity for quick solidification of the LPBF process in expediting the solid solution of B element, which increased both lattice distortion and dislocations within the Fe-Ga matrix. These factors contributed to an elevation in the density of the modified-D03 phase structure. Moreover, the prepared Fe-Ga-B alloys also exhibited a 〈001〉 preferred grain orientation caused by the high thermal gradients during the LPBF process. As a result, a maximum magnetostriction coefficient of 105 ppm was achieved in the (Fe81Ga19)98.5B1.5 alloy. In alternating magnetic fields, all the LPBF-prepared alloys showed good dynamic magnetostriction response without visible hysteresis, while the (Fe81Ga19)98.5B1.5 alloy presented a notable enhancement of ∼30 % in magnetostriction coefficient when compared with the Fe81Ga19 alloy. Moreover, the (Fe81Ga19)98.5B1.5 alloy exhibited favorable biocompatibility and osteogenesis, as confirmed by increased alkaline phosphatase (ALP) activity and the formation of mineralized nodules. These findings suggest that the B-doped Fe-Ga alloys combined with the LPBF technique hold promise for the development of bulk magnetostrictive alloys that are applicable for bone repair applications.