You still cut the weight by 60% and you still have good safety margins. This isn't a big deal if you are taking a part that is over designed by 50x and reducing that to 20x. That, and the fatigue and impact properties are very poor. This is a big deal in alloys that are not cubic structure (such as Ti) because you different strength, fatigue, modulus, and even CTE in different orientations within the same part. The biggest problem with AM today is that you don't what microstructure/properties you will have until you make a part and then destructively test it. They are controlling heat input and solidification rates so that hey can grow new tips with the original single crystal orientation. They are rebuilding about 0.050-0.090" on the tips of the blades that was lost over time to seal wear. There is a company repairing turbine blades by AM.
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