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Laser powder bed fusion (L-PBF) of metals enables the manufacturing of highly complex geometries which opens new application fields in the medical sector, especially with regard to personalized implants. In comparison to conventional manufacturing techniques, L-PBF causes different microstructures, and thus, new challenges arise. The main objective of this work is to investigate the influence of different manufacturing parameters of the L-PBF process on the microstructure, process-induced porosity, as well as corrosion fatigue properties of the magnesium alloy WE43 and as a reference on the titanium alloy Ti-6Al-4V. In particular, the investigated magnesium alloy WE43 showed a strong process parameter dependence in terms of porosity (size and distribution), microstructure, corrosion rates, and corrosion fatigue properties. Cyclic tests with increased test duration caused an especially high decrease in fatigue strength for magnesium alloy WE43. It can be demonstrated that, due to high process-induced surface roughness, which supports locally intensified corrosion, multiple crack initiation sites are present, which is one of the main reasons for the drastic decrease in fatigue strength.

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Future space exploration will focus on destinations beyond the Earth’s orbit, which necessitates new technologies such as In-Space Resource Utilization. This paper presents a technological approach for the processing of lunar regolith via an adapted laser based Additive Layer Manufacturing method, which needs no binding additives or other supply from Earth. In support of large scaled structure construction on the lunar surface, the proposed Selective Laser Melting technology has the potential to drastically lower the transportation needs of such a mission while enabling high flexibility.