Managing the inevitable microstructural and property heterogeneity in powder bed fusion Ti-6Al-4V parts via heat treatment

Abstract

This study investigates the effects of the commonly-observed microstructure heterogeneity from the metal electron beam powder bed fusion (PBF-EB) processes and how it evolves following the associated heat treatment (HT), on the tensile behaviour of Ti-6Al-4V alloy. A strain gradient crystal plasticity finite element (CPFE) method is employed using physically-based dislocation mechanics to capture the microstructure-sensitive size effect. Microstructural characterization is performed using electron backscatter diffraction (EBSD) of the as-built and post-HT specimens, with measurements of grain morphology, phase, and texture extracted from the bottom and top regions of specimens, used to construct the CPFE models. The dual-phase CPFE model represents α (hcp) and β (bcc) basket-weave morphology, typical in Ti-6Al-4V, with accurate PBF-induced texture definitions defined directly from the measured EBSD data. Key microstructural features exhibiting a gradient include lath width and phase fraction. The effects of as-built microstructural gradient in a single component include an increase of lath width by 43 %, and the beta phase fraction, from bottom to top. The CPFE models successfully predict the effect of HT and microstructural gradient on tensile response, specifically yield stress and initial hardening rate. The role of dislocation density and the associated influence of lath width on yield stress are empirically correlated for the structure-property design of PBF-EB metals. This study also demonstrates the homogenising effect of the heat treatment; effectively eradicating the microstructural gradient observed in as-built specimens.