Abstract
In this study, a multi-hopper laser deposition system is used to additively manufacture functionally graded Ti-6Al-4V to 304L stainless steel components with a vanadium interlayer. Grain morphology, phase, and composition are mapped along the component gradients with electron backscatter diffraction (EBSD) and energy dispersive X-ray spectroscopy (EDS), and mechanical property changes are assessed utilizing Vickers hardness and nanoindentation. Precipitation of brittle intermetallic compounds such as FeTi and the formation of an Fe-V-Cr sigma phase are confirmed to be the causes of mid-fabrication cracking in the components. Guided by multicomponent phase diagrams, alternate paths in composition space are proposed to strategically avoid unfavorable phase formation along the gradient. Composition-dependent adjustment of process parameters is also proposed to reduce the prevalence of observed powder inclusions, homogenize grain morphology, and improve component mechanical properties.
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