This book offers a process-chain perspective on Laser Powder Bed Fusion (LPBF) and Hot Isostatic Pressing (HIP) for Ti-6Al-4V, focusing on how defect characteristics govern high cycle fatigue and mechanical performance. It shows how productivity-driven strategies, such as hull-bulk and in-situ shelling, can be implemented achieving industrial standards.

The research examines how LPBF parameters define the initial defect state, and how HIP modifies these defects depending on their size, shape, and connectivity. By separating and then conceptually integrating printing and post-processing, it provides an understanding of the mechanisms linking process parameters, defect evolution, and mechanical performance. Particular emphasis is placed on the trade-off between productivity and quality, the limitations of common qualification metrics such defect population.

Further, this work addresses a key industrial problem: how to increase LPBF productivity and when HIP can effectively compensate for process-induced defects. It provides researchers and engineers with a framework for optimizing LPBF and HIP together, based on defects characterization.

This book is intended for researchers, doctoral students, and industrial engineers working in additive manufacturing, materials processing, and fatigue-critical applications of Ti-6Al-4V.

Viviane Kettermann Fernandes studied Materials Engineering at the Universidade Federal de Santa Catarina (UFSC) in Florianópolis, Brasil, until 2018, graduating with an engineering degree. During her studies, she gained extensive experience through several research and industrial internships in laser-based materials processing, metallographic analysis, the development of polymer-derived ceramics, the production of glass foams from waste, and the investigation of high-temperature-resistant martensitic steels.

In 2018, she joined Aalberts Material Technology in Hamburg as an R&D Engineer, where she was involved in industrial research and development projects until 2022, including work directly related to additive manufacturing (AM) and hot isostatic pressing (HIP). Since 2022, she has been working as a Materials Engineer and Quality Manager at OWL GmbH in Aachen, also with a strong industrial focus on hot isostatic pressing.

In 2026, she completed her doctoral degree under Prof. Dr.-Ing. Claus Emmelmann at the Institute of Laser and Systems Engineering (iLAS) at Hamburg University of Technology (TUHH).