Defect recrystallization in subtransus hot isostatic pressing of electron beam powder bed fusion Ti-6Al-4V

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Post-build hot isostatic pressing (HIP) is a widely used method to close as-built defects (gas or lack-of-fusion porosity) in additively manufactured (AM) metal parts. Pore closure during this process often creates clusters of equiaxed grains, in contrast to coarse and directional as-built microstructures widely seen in AM metals. Understanding the mechanisms behind the formation of such microstructures is desirable for controlling anisotropy and improving mechanical properties of AM parts. Prior work has attributed defect-induced equiaxed grains to recrystallization during the HIP process; however the specifics of this recrystallization process have not been explored. This work systematically analyzes the grain structure, orientation, and misorientations of electron beam powder bed fusion (PBF-EB) Ti-6Al-4V to identify the mechanisms by which clusters of equiaxed grains can form during HIP of as-built microstructures. A combination of two mechanisms, dynamic recovery (DRV) and continuous dynamic recrystallization (CDRX), explains the phenomena. Evidence for both these processes is found in small rotations in crystallographic orientation, localized strains around prior pore defects, and specific misorientation distributions. Only subtransus HIP of Ti-6Al-4V was explored in this work. However, the mechanisms presented here are thought to contribute to recrystallization in other HIP processes whether for super-transus Ti-6Al-4V, β-Ti alloys, other alloy systems, or non PBF-EB build processes. These results build upon prior efforts to identify specific mechanisms by which refined microstructures can be achieved in as-HIPed AM metals, improving microstructural control and providing another pathway for microstructural tailoring via AM of metals.