Abstract
A new type of pore was discovered during electron beam freeform fabrication of Ti-6-Al-4-V alloy. Unlike common metallurgical pores, the new pore has near-spherical smooth contour with a unique ball-filled microstructure. This pore may have originated from the mixed bubbles combining metallic vapor and dissolved gas. The V, Ti, and Al vapors undergo sequential condensation. The first deposited V atoms provide cores for heterogeneous nucleation. The nuclei grow into small balls under rapid cooling rate.
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