Additive Manufacturing Titanium Research Articles

Ti6Al4V-0.72H on the Establishment of Flow Behavior and the Analysis of Hot Processing Maps

Significant columnar grains usually occur in the metallurgical microstructure of laser additive manufacturing, and plastic deformation introduced into additive manufacturing can significantly refine grain size. Due to the high deformation resistance and difficult deformation of titanium alloys, reducing the high-temperature deformation resistance of additive manufacturing titanium alloys is essential to facilitating the implementation of online rolling processes. High-temperature compression of titanium alloys was performed on a Gleeble-3800. It was found that the flow stress of the alloy decreased when the strain of the alloy decreased or the deformation temperature increased. The flow behavior of titanium alloys at high temperatures was investigated with the help of a Z-parameter flow model and multiple linear regression model. A positive correlation was found between the experimental and predicted values of the alloy under the multiple linear regression model, with a correlation coefficient of 0.98 and its error of 13.5%, which could better predict the flow stress values. In addition, hot processing maps were established, and the optimal deformation conditions were determined to provide some theoretical guidance for subsequent experiments.

Novel flat-top laser-aided cold metal transfer additive manufacturing for titanium alloy: Arc characteristics, microstructure, and tensile properties

In this paper, a novel flat-top laser-aided cold metal transfer additive manufacturing (F-LCAM) method is proposed for titanium alloys to restrict internal defects and anisotropy of mechanical properties in large-scale additive-manufactured titanium structures. The proposed method uses a flat-top laser to stabilise the drifting cathode spot and suppress the irregular shape of the weld deposit by promoting thermionic emission on the molten pool surface. Compared to the cold metal transfer additive manufacturing (CMT-AM) process, the auxiliary flat-top laser promotes the wettability of the molten pool and increases the contact angle of deposition from 95° to 142° in an F-LCAM sample. The non-destructive X-ray testing (NDT) results of multi-bead multilayer deposition showed that the defects caused by the pool weld bead morphology were effectively suppressed. Attributed to fluid flow in the melt pool enhanced by the flat-top laser, the dendritic arms were broken, columnar β grains in the F-LCAM sample were finer than in CMT-AM sample, and the aspect ratios of prior-β grains decreased from approximately 6 to 1. The F-LCAM sample exhibited a higher elongation and lower anisotropy than the CMT-AM sample. Defects were observed on the fracture surfaces of the CMT-AM vertical samples, which reduced the elongation of the CMT-AM samples to lower than that of the F-LCAM sample. The ultimate tensile strength, yield strength, and elongation of the multi-bead multilayer deposition met the standards of as-forged Ti6321 titanium alloy, indicating that the Ti6321 titanium alloy structure fabricated by the F-LCAM process has acceptable tensile properties for engineering applications.

Variational mode decomposition based self-adaptive denoising imaging method for ultrasonic array testing of coarse-grained titanium alloys processed by additive manufacturing

The coarse columnar grain structure in titanium alloys processed by additive manufacturing leads to strong grain noise in ultrasonic testing, which affects the accurate detection and quantification of its defects. In this paper, a self-adaptive denoising imaging method for ultrasonic array testing is proposed based on variational mode decomposition (VMD). The proposed method uses VMD to decompose complex ultrasonic signals in full matrix capture (FMC) data collected by a linear ultrasonic array transducer. According to the particle swarm optimization (PSO) method, VMD parameters for FMC methods of the total focusing method (TFM), the plane wave imaging (PWI), and the Hadamard spatial encoding are self-adaptively determined. The evaluation parameters are set to select the intrinsic mode function components by VMD to complete the denoising reconstruction and imaging of FMC data. An additive-manufactured titanium alloy specimen was used to verify the improvement of defect detection capability by PSO-VMD denoising method. For a defect at large thickness in the specimen, compared with the conventional TFM and PWI methods, VMD denoising method based on the Hadamard spatial encoding can improve the signal-to-noise ratio by 7.7 dB and 9.0 dB, and reduce the quantitative error by 74 % and 68 %.

Current applications of 3D printing in dental implantology: Ascoping review mapping the evidence.

This scoping review aimed to identify the available evidence in the use of 3D printing technology in dental implantology. Due to the broad scope of the subject and its application in implantology, three main areas of focus were identified: (1) customized dental implants, (2) manufacturing workflow for surgical implant guides, and (3) related implant-supported prostheses factors, which include the metallic primary frameworks, secondary ceramic or polymer superstructures, and 3D implant analog models. Online databases (Medline, Cochrane, Embase, and CINAHL) were used to identify the studies published up to February 2023 in English. Two experienced reviewers performed independently the screening and selection among the 1737 studies identified. The articles evaluated the additive manufacturing (AM) technology, materials, printing, and post-processing parameters regarding dental implantology. The 132 full-text studies that met the inclusion criteria were examined. Thirteen studies of customized dental implants, 22 studies about the workflow for surgical implant guides, and 30 studies of related implant-supported prostheses factors were included. (1) The clinical evidence about AM titanium and zirconia implants is scarce. Early data on survival rates, osseointegration, and mechanical properties are being reported. (2) 3D printing is a proven manufacturing technology to produce surgical implant guides. Adherence to the manufacturer's instructions is crucial and the best accuracy was achieved using MultiJet printer. (3) The quality of 3D printed prosthetic structures and superstructures is improving remarkably, especially on metallic alloys. However, better marginal fit and mechanical properties can be achieved with milling technology for metals and ceramics.

Complementary Methods for the Assessment of the Porosity of Laser Additive-Manufactured Titanium Alloy.

The method of making parts through additive manufacturing (AM) is becoming more and more widespread due to the possibility of the direct manufacturing of components with complex geometries. However, the technology's capacity is limited by the appearance of micro-cracks/discontinuities during the layer-by-layer thermal process. The ultrasonic (US) method is often applied to detect and estimate the location and size of discontinuities in the metallic parts obtained by AM as well as to identify local deterioration in structures. The Ti6Al4V (Ti64) alloy prepared by AM needed to acquire a high-quality densification if remarkable mechanical properties were to be pursued. Ultrasonic instruments employ a different type of scanning for the studied samples, resulting in extremely detailed images comparable to X-rays. Automated non-destructive testing with special algorithms is widely used in the industry today. In general, this means that there is a trend towards automation and data sharing in various technological and production sectors, including the use of intelligent systems at the initial stage of production that can exclude defective construction materials, prevent the spread of defective products, and identify the causes of certain instances of damage. Placing the non-destructive testing on a completely new basis will create the possibility for a broader analysis of the primary data and thus will contribute to the improvement of both inspection reliability and consistency of the results. The paper aims to present the C-scan method, using ultrasonic images in amplitude or time-of-flight to emphasize discontinuities of Ti64 samples realized by laser powder-bed fusion (L-PBF) technology. The analysis of US maps offers the possibility of information correlation, mainly as to flaws in certain areas, as well as distribution of a specific flaw in the volume of the sample (flaws and pores). Final users can import C-scan results as ASCII files for further processing and comparison with other methods of analysis (e.g., non-linear elastic wave spectroscopy (NEWS), multi-frequency eddy current, and computer tomography), leading to specific results. The precision of the flight time measurement ensures the possibility of estimating the types of discontinuities, including volumetric ones, offering immediate results of the inspection. In situ monitoring allows the detection, characterization, and prediction of defects, which is suitable for robotics. Detailing the level of discontinuities at a certain location is extremely valuable for making maintenance and management decisions.

Micro-deformation behavior of laser melting deposited multi-gradient TC4/TC11 alloy under tension–tension cyclic loading

The microstructure of additive manufacturing titanium alloy is closely related to its mechanical properties. In this study, a TC4/TC11 titanium alloy with 20 layers was prepared by laser melting deposition (LMD) technology. Microstructure analysis revealed a transformation of the columnar grains into equiaxed grains along the build direction (BD), accompanied by the presence of heat affected zone (HAZ) bands and pore defects. The defect families of specimens in different directions were characterized by X-ray micro-computed tomography (micro-CT). The porosity of BD specimens was 0.0021%, and the porosity of the transverse direction (TD) specimens was 0.0001%, indicating that the material was dense. Specimens with different directions were subjected to tension–tension cyclic loading, and their deformation was analyzed by digital image correlation (DIC). The results show that the presence of noticeable pore defects leads to crack initiation around these regions due to local strain concentration. Moreover, the dispersion and anisotropy of mechanical properties are attributed to the influence of porosity and microstructure deformation, the latter being the dominant factor. In addition, the deformation mechanism and failure mode of the microstructure in LMD TC4/TC11 are proposed in this paper. The deformation of the α laths of TD specimen is hindered by the columnar grain boundary, resulting in improved resistance against crack nucleation and propagation compared to the BD specimen.

Strengthening effect in laser metal deposited Ti6Al4V alloy via layer-by-layer ultrasonic impact treatment

The present work investigates the influence of incorporation of the layer-by-layer ultrasonic impact treatment (UIT) into the laser metal deposition (LMD) processing of Ti6Al4V alloy. The microstructure and mechanical properties of the samples with/without the assistance of UIT are comparatively studied. The curved shape boundaries of α/α′ phase with inconsistent misorientation angles and the ultra-fine α phase are observed in the UIT-assisted LMD (ULMD) sample. The α/α′ phase in the ULMD sample is characterized by high-density dislocations, larger lattice strain and distortion in comparison with that in the LMD sample. An ultimate tensile strength of 1386 MPa is obtained in the ULMD sample that exceeds that of the LMD sample by 373 MPa and is superior to the values reported in majority of the previous works. Crystallographic orientation change, increased dislocation density and α/α′ phase lattice distortion, and formation of ultra-fine α grains are found to influence the properties. The present work provides an in-depth understanding of the mechanisms/factors influencing the mechanical strengths of additive-manufactured titanium alloys.

Investigation of fatigue behavior of laser powder bed fusion Ti-6Al-4V: Roles of heat treatment and microstructure

High cycle fatigue (HCF) performance of additive manufactured (AM) titanium products is of great significance for its structural and functional applications. However, tying fatigue performance to the complex microstructures in AM titanium alloys is challenging. The work here carried out a thorough investigation into the influence of microstructures (particularly the grain boundary α-phase (GB-α) with varied morphologies) on the fatigue performance of laser powder bed fusion (LPBF) Ti–6Al–4V (Ti-64). Results showed that the improvement in the high-cycle fatigue life of LPBF Ti-64 could be achieved by the formation of low aspect ratio α lath and discontinuous GB-α via optimized post-fabrication heat treatment. Discontinuous GB-α could fully accommodate the deformation, improving the fatigue crack propagation resistance. Moreover, α lath with a low aspect ratio could lead to less strain accumulation on the interface between adjacent α lath, and thereby inhibit the crack initiation at these interfaces. This study enhances the understanding of how LPBF-induced complex microstructures influence fatigue behavior, and provides a pathway for the improvement of fatigue performance of additive manufactured titanium alloy.

Osseointegration in additive-manufactured titanium implants: A systematic review of animal studies on the need for surface treatment

The objective of the systematic review is to find an answer to a question: “Do surface treatments on titanium implants produced by additive manufacturing improve osseointegration, compared to untreated surfaces?“. This review followed the Preferred Reporting Items for Systematic Review and Meta-Analysis (PRISMA 2020) and was registered in the International Prospective Register of Systematic Reviews (PROSPERO) (CRD42022321351). Searches were performed in PubMed, Scopus, Science Direct, Embase, and Google Scholar databases on March 22nd, 2022. Articles were chosen in 2 steps by 2 blinded reviewers based on previously selected inclusion criteria: articles in animals that addressed the influence of surface treatments on osseointegration in implants produced by additive manufacturing. Articles were excluded that (1) did not use titanium surface, 2) that did not evaluate surface treatments, 3) that did not described osseointegration, 4) Studies with only in vitro analyses, clinical studies, systematic reviews, book chapters, short communications, conference abstracts, case reports and personal opinions.). 1003 articles were found and, after applying the eligibility criteria, 17 were used for the construction of this review. All included studies found positive osseointegration results from performing surface treatments on titanium. The risk of bias was analyzed using the SYRCLE assessment tool. Surface treatments are proposed to promote changes in the microstructure and composition of the implant surface to favor the adhesion of bone cells responsible for osseointegration. It is observed that despite the benefits generated by the additive manufacturing process in the microstructure of the implant surface, surface treatments are still indispensable, as they can promote more suitable characteristics for bone-implant integration. It can be concluded that the surface treatments evaluated in this systematic review, performed on implants produced by additive manufacturing, optimize osseointegration, as it allows the creation of a micro-nano-textured structure that makes the surface more hydrophilic and allows better contact bone-implant.

In Situ Tensile Observation of the Effect of Annealing on Fracture Behavior of Laser Additive Manufactured Titanium Alloy.

The use safety of laser additive manufactured (LAM) titanium alloys is closely related to each one's fracture failure mode. In this study, in situ tensile tests were carried out to study the deformation and fracture mechanisms of LAM Ti6Al4V titanium alloy before and after annealing treatment. The results showed that plastic deformation promoted slip bands to occur inside the α phase and shear bands to generate along the α/β interface. In the as-built sample, cracks initiated in the equiaxed grains and propagated along the columnar grain boundary, showing a mixed fracture mode. However, it transformed into a transgranular fracture after annealing treatment. The widmanstatten α phase acted as a barrier for slip movement and improved the crack resistance of grain boundaries.

Additively manufactured Ti-29Nb-21Zr shows improved oxide polarization resistance versus Ti-6Al-4V in inflammatory simulating solution.

Retrieval studies in the past two decades show severe corrosion of titanium and its alloys in orthopedic implants. This damage is promoted by mechanically assisted crevice corrosion (MACC), particularly within modular titanium-titanium junctions. During MACC, titanium interfaces may be subject to negative potentials and reactive oxygen species (ROS), generated from cathodic activation and/or inflammation. Additive manufacturing (AM) may be able to produce new, corrosion-resistant titanium alloys and admixtures that are less susceptible to these adverse electrochemical events. In this study, we characterize the impedance and corrosion properties of three new AM titanium materials, including Ti-6Al-4V with added 1% nano-yttria stabilized ZrO2 , admixed Ti-29Nb-21Zr, and pre-alloyed Ti-29Nb-21Zr. We aim to elucidate how these materials perform when subjected to high ROS solutions. We include conventionally and additively manufactured Ti-6Al-4V in our study as comparison groups. A 0.1 M H2 O2 phosphate-buffered saline (PBS) solution, simulating inflammatory conditions, significantly increased biomaterial OCP (-0.14 V vs. Ag/AgCl) compared to PBS only (-0.38 V, p = .000). During anodic polarization, Ti-6Al-4V passive current density more than doubled from 1.28 × 10-7 to 3.81 × 10-7  A/cm2 when exposed to 0.1 M H2 O2 . In contrast, Ti-29Nb-21Zr passive current density remained relatively unchanged, slightly increasing from 7.49 × 10-8 in PBS to 9.31 × 10-8 in 0.1 M H2 O2 . Ti-29Nb-21Zr oxide polarization resistance (Rp ) was not affected by 0.1 M H2 O2 , maintaining a high value (1.09 × 106 vs. 1.89 × 106  Ω cm2 ), while Ti-6Al-4V in 0.1 M H2 O2 solution had significantly diminished Rp (4.38 × 106 in PBS vs. 7.24 × 104  Ω cm2 in H2 O2 ). These results indicate that Ti-29Nb-21Zr has improved corrosion resistance in ROS containing solutions when compared with Ti-6Al-4V based biomaterials.

Additive manufacturing titanium powder oxygen variation within a single powder bed due to differences in powder size and oxygen content

Additive manufacturing titanium powder oxygen variation within a single powder bed due to differences in powder size and oxygen content

Role of structural hierarchy on mechanics and electrochemistry of wire arc additive manufactured (WAAM) single phase titanium

The absence of understanding of correlations between structure, mechanics, and electrochemical behavior in single-phase additive-manufactured titanium components impedes the advancement of large-scale processing. The present study addresses this scientific knowledge gap by investigating the evolution of structural hierarchy and its impact on the hardness and corrosion resistance of wire arc additive manufactured (WAAM) commercially pure titanium (cp-Ti) along three mutually orthogonal deposition directions. Integrated X-ray diffraction and optical microscopy revealed that a single-phase α-Ti monolithic structure is devoid of observable deposition tracks and interfaces with traces of titanium oxide. Homogeneous nucleation in the single phase at low undercooling and slow solidification rates during WAAM resulted in coarse grains of size 1 mm. The grains are randomly oriented with slight preferential texture along the hexagonal close-packed basal {0001} planes due to their parallel orientation with the close-packed body-centered cubic {011} plane during the β – α phase transition. The single-phase structure results in a uniform distribution of microhardness along layer-by-layer buildup direction and the bulk with an average of 1.6 GPa, which is about 80 % of conventionally cast cp-Ti. An increased dislocation density at the surface and from thermal strain during WAAM enhances nanohardness to 3.0 GPa. The absence of galvanic potential difference between two adjacent grains and the coarse size imparts high corrosion resistance with a rate of 80 × 10−5 mm per year, less than 50 % of other additive-manufactured titanium alloys. Overall, this study advances the state-of-the-art in homogenous, single-phase WAAM processing as a potential large-sale additive manufacturing alternative to conventionally processed Ti components.

The State of the Art in Machining Additively Manufactured Titanium Alloy Ti-6Al-4V

Titanium alloys are extensively used in various industries due to their excellent corrosion resistance and outstanding mechanical properties. However, titanium alloys are difficult to machine due to their low thermal conductivity and high chemical reactivity with tool materials. In recent years, there has been increasing interest in the use of titanium components produced by additive manufacturing (AM) for a range of high-value applications in aerospace, biomedical, and automotive industries. The machining of additively manufactured titanium alloys presents additional machining challenges as the alloys exhibit unique properties compared to their wrought counterparts, including increased anisotropy, strength, and hardness. The associated higher cutting forces, higher temperatures, accelerated tool wear, and decreased machinability lead to an expensive and unsustainable machining process. The challenges in machining additively manufactured titanium alloys are not comprehensively documented in the literature, and this paper aims to address this limitation. A review is presented on the machining characteristics of titanium alloys produced by different AM techniques, focusing on the effects of anisotropy, porosity, and post-processing treatment of additively manufactured Ti-6Al-4V, the most commonly used AM titanium alloy. The mechanisms resulting in different machining performance and quality are analysed, including the influence of a hybrid manufacturing approach combining AM with conventional methods. Based on the review of the latest developments, a future outlook for machining additively manufactured titanium alloys is presented.

Fixation of Iliac Avulsion Fracture Using Additive Manufacturing Titanium Mesh after DCIA Flap Harvesting: Case Report

Jaw defects can have a variety of causes, including tumors, trauma, and osteomyelitis. The reconstruction of jaw defects has been improved with the free flap technique and sophisticated microvascular techniques. A deep circumflex iliac artery (DCIA) flap provides a large amount of bone for the reconstruction of the mandible. However, various complications and side effects, such as abnormal hip contour, hernia, severe bleeding tendency, gait disturbance, and hypoesthesia, can occur. Iliac bone fracture is not a common complication after DCIA flap harvesting, because the anterior superior iliac spine (ASIS) can include the harvested flap. If an iliac avulsion fracture occurs, various treatment options exist. If severe dislocation of the bone fragment exists, open reduction and internal fixation are required. At this time, orthopedic implants composed of various materials can be used. Among these, when using a 3D-fabricated implant using a Ti6Al4V alloy, the accuracy of the size and shape is excellent, and it can have mechanical–biocompatible advantages. In this study, we report cases of iliac bone fracture after reconstruction of the jaw with a DCIA flap and the treatment modality using a 3D-printed, patient-specific titanium implant.

Microplasma spraying of hydroxyapatite coatings on additive manufacturing titanium implants with trabecular structures

Abstract This paper presents new results of microplasma spraying (MPS) of laboratory-synthesized hydroxyapatite (HA) powder coatings onto trabecular substrates obtained by selective laser melting (SLM) of a certified titanium medical alloy powder. The aim of the study was to establish the possibility of combining the technologies of MPS and additive manufacturing (AM) for the possible production of custom-designed implants with increased surface biocompatibility, as well as to establish the MPS parameters that ensure chemical purity of the HA coating and satisfactory adhesion of the coatings to the substrate. The structural-phase compositions of the initial HA powder and the plasma-sprayed HA coating were studied by X-ray diffraction analysis and transmission electron microscopy, and the adhesion strength of the coating was tested according to the F1147 standard of the American Society for Testing and Materials (ASTM). The main results of the study are the following: the application of the MPS technology for HA coating with an average thickness of 150±50 μm on trabecular substrates obtained by the SLM method has been shown. The parameters of MPS of HA coatings onto titanium implants with a trabecular surface have been established. It is also proved that using the appropriate MPS parameters, it is possible to obtain a HA coating with a 95% level of HA phases, 93% level of crystallinity, and the adhesion strength to the trabecular substrate of 24.7±5.7 MPa, which complies with the requirements of the international medical standard (International Organization for Standardization [ISO] 13779-2:2018). These results are of significance for a wide range of researchers developing plasma spray technologies for the manufacture of biocompatible coatings.

The Promotion of Mechanical Properties by Bone Ingrowth in Additive-Manufactured Titanium Scaffolds.

Although the initial mechanical properties of additive-manufactured (AM) metal scaffolds have been thoroughly studied and have become a cornerstone in the design of porous orthopaedic implants, the potential promotion of the mechanical properties of the scaffolds by bone ingrowth has barely been studied. In this study, the promotion of bone ingrowth on the mechanical properties of AM titanium alloy scaffolds was investigated through in vivo experiments and numerical simulation. On one hand, the osseointegration characteristics of scaffolds with architectures of body-centred cubic (BCC) and diamond were compared through animal experiments in which the mechanical properties of both scaffolds were not enhanced by the four-week implantation. On the other hand, the influences of the type and morphology of bone tissue in the BCC scaffolds on its mechanical properties were investigated by the finite element model of osseointegrated scaffolds, which was calibrated by the results of biomechanical testing. Significant promotion of the mechanical properties of AM metal scaffolds was only found when cortical bone filled the pores in the scaffolds. This paper provides a numerical prediction method to investigate the effect of bone ingrowth on the mechanical properties of AM porous implants, which might be valuable for the design of porous implants.

Simultaneous improvement of strength and elongation of laser melting deposited Ti-6Al-4V titanium alloy through three-stage heat treatment

This study reported a strategy of three-stage heat treatment to simultaneously improve yield strength (YS), ultimate tensile strength (UTS) and elongation (EL) of laser melting deposited (LMDed) Ti-6Al-4V titanium alloy . After the three-stage heat treatment, the basketweave microstructure consisting of acicular α laths in the as-built sample was transformed to a multiscale-α microstructure consisting of the coarse-plate α, fine-plate α and ultrafine α in the heat-treated sample. The effect of microstructure on the tensile properties was revealed via in-situ tensile test combined with the analysis of the deformation and fracture mechanism . Although the coarse-plate α in heat-treated sample is larger than the acicular α in as-built sample, the combination of multiscale α grains with a certain relative content aroused an increment of the YS from 879 ± 28 MPa in as-built sample to 973 ± 9 MPa in heat-treated sample. The good deformation compatibility among the multiscale α grains impeded the crack propagation effectively, which resulted in the improvement of the EL from 14 ± 2% to 16 ± 1%. Furthermore, the improvement of the EL enhanced the dislocation multiplication and strain hardening in the multiscale α microstructure to induce the increment of the UTS from 945 ± 40 MPa to 1092 ± 20 MPa. The results could provide a guidance for tailoring microstructure and improving the strength and ductility of additive manufacturing titanium alloy.

In-situ grain structure control in directed energy deposition of Ti6Al4V

In metal additive manufacturing (AM), long columnar grains along the building direction due to highly directional thermal gradients often lead to a strong texture and severe anisotropy in mechanical properties of the deposits, which significantly impair part qualification and targeted applications. Here, a novel depositing strategy by periodically alternating processing parameters is designed to partially preserve the equiaxed grains resulted from the columnar-to-equiaxed transition at the top of each deposited layer and, at the same time, to interrupt the epitaxial growth of columnar grains in AM titanium alloy. With the help of the competitive growth of the new grains and the potential coarsening effect during subsequent thermal-cycles, a microstructure of full equiaxed prior-β grains in Ti6Al4V fabricated by laser directed energy deposition (DED) is finally obtained without either using any auxiliary equipment or adjusting alloy chemistry like previous researches. This further contributes to a superior mechanical property and a remarkable reduction on both the crystallographic textures and the property anisotropy.

Material characterisation of additive manufacturing titanium alloy (Titanium 6Al-4V) for quality control and properties evaluations

ABSTRACT Current additive manufacturing (AM) technologies use various raw materials such as plastics and metals to fabricate parts. Moreover, the increasing use of metallic parts makes AM applicable to commercial use such as aeronautical, and medical field. For this reason, manufacturing process quality evaluation becomes essential to achieve higher quality products. Quality control and material property assessment for AM parts is a major challenge due to the complexity of the materials and geometry of the parts. Non-Destructive Testing (NDT) is being proposed as a cost-effective way to evaluate the quality of the product. For this reason, the nanoindentation, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) techniques are being used as useful forms of NDT techniques to assess the quality and material characteristics in metal AM samples. The material properties of additively manufactured Titanium 6Al-4 V alloy are studied to verify the in-situ process monitoring published results at different manufacturing process conditions. The comparison of material properties of three different process conditions made by direct energy deposition (DED) metal additive manufacturing is discussed to understand the variation. The results show that the characteristics of materials are a function of process parameters and have a strong correlation to the expected in-situ monitoring indicators.