Abstract
Standard electron beam powder-bed fusion Ti-6Al-4V powder recovery and hot-isostatic pressing has been found to result in a surface layer microstructure change to globular α/β. Thickness control of this surface layer up to 15μm was demonstrated by varying powder recovery blasting working distance and duration. This surface globular layer was found to improve high-cycle rotating bending fatigue strength at 107 cycles by 60 MPa for specimens with smooth surfaces. The same trend was not observed for specimens with as-built surface roughness because globularization did not occur at dominant fatigue crack initiation sites; the roots of deep surface crevices.
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