Effects of processing on microstructure and mechanical properties of a titanium alloy (Ti–6Al–4V) fabricated using electron beam melting (EBM), part 1: Distance from build plate and part size

Abstract

Selective electron beam melting (EBM) is a layer-by-layer additive manufacturing technique that shows great promise for fabrication of medical devices and aerospace components. Before its potential can be fully realized, however, a comprehensive understanding of processing–microstructure–properties relationships is necessary. Titanium alloy (Ti–6Al–4V) parts were built in a geometry developed to allow investigation of the following two intra-build processing parameters: distance from the build plate and part size. Microstructure evaluation (qualitative prior-β grain size, quantitative α lath thickness), tensile testing, and Vickers microhardness were performed for each specimen. Microstructure and mechanical properties, including microhardness, were not found to vary as a function of distance from the build plate, which was hypothesized to be influenced by the build plate preheating associated with the EBM process. Part size, however, was found to influence ultimate tensile strength (UTS) and yield strength (YS) by less than 2% over the size range investigated. A second order effect of thermal mass might also have influenced these results. Differences were observed between the EBM Ti–6Al–4V microstructure of this work and the expected acicular or Widmanstätten microstructure normally achieved through annealing above the β transus. Therefore, a different relationship between α lath thickness and mechanical properties might be expected.