As-built Microstructure Research Articles

Tensile Properties of Ex-Situ Ti-TiC Metal Matrix Composites Manufactured by Laser Powder Bed Fusion.

Titanium-based Metal Matrix Composites (MMCs) manufactured by additive manufacturing offer tremendous lightweighting opportunities. However, processing the high reinforcement contents needed to substantially improve elastic modulus while conserving significant ductility remains a challenge. Ti-TiC MMCs fabricated in this study reported fracture strains in tension up to 1.7% for a Young's modulus of 149 GPa. This fracture strain is 30% higher than the previously reported values for Ti-based MMCs produced by Laser Powder Bed Fusion (LPBF) displaying similar Young's moduli. The heat treatment used after the LPBF process leads to the doubling of the fracture strain thanks to the conversion of TiCx dendrites into equiaxed TiCx grains. The as-built microstructure shows both un-dissolved TiC particles and sub-stoichiometric TiC dendrites resulting from the partial dissolution of TiC particles. The reduction of the C/Ti ratio in TiC during the process results in an increase in the reinforcement content, from a nominal 12 vol% to an effective 21.5 vol%. The variation of the TiC lattice constant with its stoichiometry is measured, and an empirical expression is proposed for its effect on TiC's Young's modulus. The lower TiC powder size distribution displayed higher mechanical properties thanks to a reduced number of intrinsic flaws.

Tailored microstructure in laser-based powder bed fusion of IN718 through novel beam shaping technology

Inconel 718, processed by Laser-based Powder Bed Fusion of Metals (PBF-LB/M), exhibits epitaxial dendrite growth, leading to an anisotropic columnar microstructure. While columnar microstructures offer creep resistance, equiaxed microstructures provide more balanced mechanical properties. Understanding how to tailor the as-built microstructure in the PBF-LB/M process remains a persistent challenge. Recent advancements in beam shaping offer solutions for customizing heat flow direction in the PBF-LB/M process and tailoring the as-built microstructure. This research aims to systematically study how the laser beam shape affects anisotropy in the as-built microstructure and tensile mechanical properties. By using an inverse calculated beam shape, called as chair-shaped, the texture strength represented by J-index was reduced from 4.6 (generated by a ring-shaped beam profile with the same beam intensity and laser process parameters) to 1.37. The study prioritizes high productivity, with a building rate of 16 mm3/s (80 μm layer thickness) across chosen process parameters compared to state-of-the-art with a build rate of 4.2 mm3/s (40 μm layer thickness). The findings indicate that rotational asymmetric laser beam profiles with a relative beam diameter of 400 μm significantly enhance productivity by broadening the process window. These profiles also have a profound impact on the microstructure and tensile properties compared to ring-shaped and core-ring laser beam profiles. The new microstructure features a notable reduction in grain size, elongation, and texture index, producing mechanical properties that are comparable to those of an isotropic microstructure.

Microstructural Stability of IN625 Reinforced by the Addition of TiC Produced by Laser Powder Bed Fusion after Prolonged Thermal Exposure.

This paper deals with the development and characterization of an Inconel 625 (IN625) reinforced with 2 wt.% of sub-micrometrical TiC particles produced by the laser powder bed fusion (LPBF) process. IN625 and IN625 2 wt.% TiC microstructural evolution was evaluated in the as-built, solution-annealed (2 h at 1150 °C), and prolonged heat-treated (2 h at 1150 °C + 100 h at 1000 °C) conditions. The IN625 and IN625 + TiC samples were successfully produced with low residual porosity (<0.15%). In the as-built conditions, both materials developed mainly columnar grains elongated to the building direction with melt pools, fine dendric structures, and small fractions of recrystallized grains. Some TiC segregations were observed in the composite, preferentially located at the melt pool boundaries. The heat treatments led to a different microstructural evolution between the base alloy and the composite. After solution annealing, the IN625 alloy was subjected to full recrystallization with a drastic reduction in hardness. Afterward, the prolonged thermal exposures for 100 h at 1000 °C provoked the formation of carbides, increasing the hardness. On the contrary, the composite retained the as-built microstructure with columnar grains in the solution-annealed and prolonged heat-treated conditions, revealing a limited formation and growth of carbides, thus resulting in a reduced hardness variation. The addition of TiC inside the IN625 enhanced the microstructural stability of the composite, preventing the recrystallization and the growth of phases occurring under prolonged thermal exposures. The current study therefore reported the effect of TiC particles on the microstructural stabilization of LPBFed IN625, with a peculiar focus on the prolonged thermal exposure at 1000 °C.

Novel Fe-rich hypo-eutectic high entropy alloy developed for laser powder bed fusion in the Al-Co-Cr-Fe-Ni-Zr system

A novel heat resistant Fe-rich hypo-eutectic high entropy alloy (HEA) was manufactured using laser powder bed fusion (LPBF). The prealloyed Al1/4Co2Cr2Fe6Ni3/2Zr powder was characterized and processed using different preheating temperatures (650°C, 700°C and 800°C). The as-built microstructure showed dissimilar morphologies throughout the melt pool, with eutectic grains of ultra fine lamella spacing (λ≈25 nm) inside the core regions, and coarser dendritic and globulitic growth patterns at the interlayer boundaries (ILBs). An annealing treatment at 1000°C for 6 h yielded a homogenous composite microstructure of a Fe-rich matrix with ∼40 % of fine dispersed Zr-rich intermetallic (IM) phases of submicron size. Synchrotron high energy x-ray diffraction (HEXRD) revealed M2Zr Laves (M = Co, Fe, Ni) as the main IM for the as-built condition and the additional growth of M23Zr6 upon annealing. Further HEXRD in-situ high temperature tests examined the lattice parameter evolution and coefficient of thermal expansion (CTE) up to 1100°C. The mechanical performance of the as-built and annealed condition was evaluated through hardness and compression testing at room temperature (RT). Additional compression testing from RT to 1000°C were conducted on the annealed condition to assess the high temperature strength and give comparison to other high temperature materials like Ni-based superalloys.

Oxygen-rich combustion behaviors and mechanisms of a new Ni-Cr-based superalloy fabricated by selective laser melting

The mechanical and combustion behavior of a new Ni-Cr-based superalloy, fabricated by selective laser melting in an atmosphere with an oxygen concentration greater than 99.5 %, was investigated through the analysis of microstructural morphology, elements distribution and combustion kinetics. The results show that heat treatment eliminated the anisotropy of the as-built microstructures and improved the tensile strength. The studied superalloy can be ignited with a combustion threshold of about 2.5 MPa–3 MPa. The burning length and burning rate increase with the increase of pressure. The selective combustion of Al, Ti, Nb, Cr, Fe, Mo, and Cu elements occurred, resulting in the dissolution of γ′, γ", and δ precipitates and formation of holes at the grain boundaries in the heat-affected zone. The microstructures exhibit large elongated grains in the melting zone and column grains in the heat-affected zone along the heat dissipation direction. The combustion products are a mixture of oxides exhibiting dendritic structures in terms of selective combustion, density, and melting point. The findings from this study enhance our comprehension of the combustion process in nickel-based superalloys, offering valuable data and guidance for the advancement of new oxygen-rich combustion-resistant superalloys.

A Comparative Study of the As-Built Microstructure of a Cold-Work Tool Steel Produced by Laser and Electron-Beam Powder-Bed Fusion

A Comparative Study of the As-Built Microstructure of a Cold-Work Tool Steel Produced by Laser and Electron-Beam Powder-Bed Fusion

Defect recrystallization in subtransus hot isostatic pressing of electron beam powder bed fusion Ti-6Al-4V

Post-build hot isostatic pressing (HIP) is a widely used method to close as-built defects (gas or lack-of-fusion porosity) in additively manufactured (AM) metal parts. Pore closure during this process often creates clusters of equiaxed grains, in contrast to coarse and directional as-built microstructures widely seen in AM metals. Understanding the mechanisms behind the formation of such microstructures is desirable for controlling anisotropy and improving mechanical properties of AM parts. Prior work has attributed defect-induced equiaxed grains to recrystallization during the HIP process; however the specifics of this recrystallization process have not been explored. This work systematically analyzes the grain structure, orientation, and misorientations of electron beam powder bed fusion (PBF-EB) Ti-6Al-4V to identify the mechanisms by which clusters of equiaxed grains can form during HIP of as-built microstructures. A combination of two mechanisms, dynamic recovery (DRV) and continuous dynamic recrystallization (CDRX), explains the phenomena. Evidence for both these processes is found in small rotations in crystallographic orientation, localized strains around prior pore defects, and specific misorientation distributions. Only subtransus HIP of Ti-6Al-4V was explored in this work. However, the mechanisms presented here are thought to contribute to recrystallization in other HIP processes whether for super-transus Ti-6Al-4V, β-Ti alloys, other alloy systems, or non PBF-EB build processes. These results build upon prior efforts to identify specific mechanisms by which refined microstructures can be achieved in as-HIPed AM metals, improving microstructural control and providing another pathway for microstructural tailoring via AM of metals.

An integrated computation framework for predicting mechanical performance of single-phase alloys manufactured using laser powder bed fusion: A case study of CoCrFeMnNi high-entropy alloy

Establishing a process-structure-property (PSP) relationship is crucial for understanding and optimizing the mechanical properties of components via laser powder bed fusion (L-PBF) additive manufacturing (AM). However, the parameters pertinent to the PSP relationship are encapsulated in a “black box” with a high dimension, resulting in relying on trial-and-error approaches to elucidate hidden associations becoming impracticable, while the acquisition of microscopic data proves financially burdensome. Thus this paper presents an integrated computation framework based on machine learning (ML) for predicting the tensile yield strengths and post-yield hardening rates of single-phase alloys fabricated through L-PBF, for efficient process optimization purposes. Research herein focuses on single-phase alloys to be built via L-PBF, taking CoCrFeMnNi high-entropy alloy as a study case, and provide an efficient integrated computation solution. The methodology proposed in this paper generates as-built microstructures associated with the varying L-PBF process parameters via cellular automata (CA). Subsequently, the mechanical responses of these microstructures are estimated by employing crystal plasticity finite element (CPFE) simulations. In addition, the approach raised in the paper leverages particle-level microstructure descriptors instead of average feature descriptors for the entire representative volume element (RVE) structure in an ML framework to predict the characteristics of the newly randomly growing grains. This research demonstrate the practicality and instructiveness of the methodology for modeling realistic grains. Then, trained ML model exhibits promising accuracy for the prediction of mechanical properties. This work showcases an integrated computation framework combining advanced materials science and ML techniques for enhancing understanding of the L-PBF process and offering valuable insights into process optimization for L-PBF-built diverse materials.

Melting mode driven tuning of local microstructure and hardness in laser powder bed fusion of 18Ni-300 maraging steel

Laser powder bed fusion (LPBF) of 18Ni-300 maraging steel has attracted abundant popularity in both academia and industry due to its superior mechanical properties and printability. Several studies showcased the optimization of process parameters based on relative density, but there is little exploration on tailoring the as-built microstructure. In this study, fully dense maraging steel samples are fabricated with three different melting modes, and they are examined for the cellular solidification microstructure, retained austenite, and the effect of cyclic reheating, the three characteristics that are unique to additively manufactured maraging steel. Microstructural discrepancies among the samples are traced back to the different cooling rate and residual heat, both of which are ultimately determined by the energy input. The findings suggest that a reasonably low energy input yields a microstructure containing fine cell size and little retained austenite, leading to higher hardness. Nanoindentation mapping reveals that the main bodies of all samples are strengthened around 13 %, likely because of the formation of precipitation zone due to four to five layers of subsequent cyclic reheating. This study demonstrates the important opportunity for microstructural tailoring, and consequently, engineering the mechanical properties of maraging steel via LPBF by controlling the solidification and subsequent cyclic reheating, which are both attributed to the printing parameters deployed.

Martensite decomposition kinetics in additively manufactured Ti-6Al-4V alloy: In-situ characterisation and phase-field modelling

Additive manufacturing of Ti-6Al-4V alloy via laser powder-bed fusion leads to non-equilibrium α′ martensitic microstructures, with high strength but poor ductility and toughness. These properties may be modified by heat treatments, whereby the α′ phase decomposes into equilibrium α+β structures, while possibly conserving microstructural features and length scales of the α′ lath structure. Here, we combine experimental and computational methods to explore the kinetics of martensite decomposition. Experiments rely on in-situ characterisation (electron microscopy and diffraction) during multi-step heat treatment from 400∘C up to the alloy β-transus temperature (995∘C). Computational simulations rely on an experimentally-informed computationally-efficient phase-field model. Experiments confirmed that as-built microstructures were fully composed of martensitic α′ laths. During martensite decomposition, nucleation of the β phase occurs primarily along α′ lath boundaries, with traces of β nucleation along crystalline defects. Phase-field results, using electron backscatter diffraction maps of as-built microstructures as initial conditions, are compared directly with in-situ characterisation data. Experiments and simulations confirmed that, while full decomposition into stable α+β phases may be complete at 650∘C provided sufficient annealing time, visible morphological evolution of the microstructure was only observed for T≥700∘C, without modification of the prior-β grain structure.

Correlation of microstructure, mechanical properties, and residual stress of 17-4 PH stainless steel fabricated by laser powder bed fusion

17-4 precipitation hardening (PH) stainless steel is a multi-purpose engineering alloy offering an excellent trade-off between strength, toughness, and corrosion properties. It is commonly employed in additive manufacturing via laser powder bed fusion owing to its good weldability. However, there are remaining gaps in the processing-structure-property relationships for AM 17-4 PH that need to be addressed. For instance, discrepancies in literature regarding the as-built microstructure, subsequent development of the matrix phase upon heat treatment, as well as the as-built residual stress should be addressed to enable reproducible printing of 17-4 builds with superior properties. As such, this work applies a comprehensive characterisation and testing approach to 17-4 PH builds fabricated with different processing parameters, both in the as-built state and after standard heat treatments. Tensile properties in as-built samples both along and normal to the build direction were benchmarked against standard wrought samples in the solution annealed and quenched condition (CA). When testing along the build direction, higher ductility was observed for samples produced with a higher laser power (energy density) due to the promotion of interlayer cohesion and, hence, reduction of interlayer defects. Following the CA heat treatment, the austenite volume fraction increased to ∼35 %, resulting in a lower yield stress and greater work hardening capacity than the as-built specimens due to the transformation induced plasticity effect. Neutron diffraction revealed a slight reduction in the magnitude of residual stress with laser power. A concentric scanning strategy led to a higher magnitude of residual stress than a bidirectional raster pattern.

Synchrotron based investigation of anisotropy and microstructure of wire arc additive manufactured Grade 91 steel

Additive manufacturing (AM) rapidly produces complex shapes crucial for energy technologies and engineering designs. In this work, the microstructure and mechanical properties of additive manufactured Grade 91 (modified 9Cr–1Mo) ferritic/martensitic (FM) steel were investigated. Computational thermodynamics, synchrotron X-ray diffraction, scanning electron microscopy, and microhardness testing were utilized to quantify microstructure (crystallographic phases, microstrain), lattice parameters, and mechanical properties as functions of the build directions and post-build heat-treatment. The as-built microstructures were found to contain a large fraction of microstrain due to two-dimensional defects, and a low-carbon martensite phase (maximum value 38.4 vol%), as quantified from the X-ray diffraction analysis. It was shown that a post-build heat-treatment can effectively remove this martensitic phase and promote the formation of desired microstructures with dispersed M23C6 carbides which was consistent with Thermo-Calc predictions. From the X-ray diffraction analysis, an ∼82.5% reduction in microstrain, a 61.5% increase in the coherent grain size and complete elimination of body-centered tetragonal (BCT) phase demonstrated that an appropriate heat-treatment of AM built FM steel yields microstructures and hardness comparable to conventionally processed steel. However, based on lattice parameter and hardness map statistics, heat-treatment on the as-manufactured steel did not eliminate anisotropy.

Effect of compositional variations on the heat treatment response in 17-4 PH stainless steel fabricated by laser powder bed fusion

17–4 precipitate hardening (PH) stainless steel is used in various applications including in the aerospace, marine, and chemical industries, largely due to its unique combination of corrosion resistance and high strength, which is achieved by the formation of nanoscale Cu-rich precipitates during aging. 17–4 PH has been widely researched for its applicability for laser powder bed fusion (LPBF). However, there are discrepancies in the literature on its heat treatment response, which seem to be linked to compositional variations. Systematic studies of the interplay between these variations and nanoscale precipitation are currently missing. Using atom probe tomography, we present a systematic study of the heat treatment responses of two variants of LPBF 17–4 PH builds fabricated from different powder feedstocks, with significant differences in N contents (High vs Low N 17–4). Both variants formed predominantly δ-ferritic as-built microstructures. The as-built High N 17–4 variant showed a higher volume fraction of austenite which further increased upon solution annealing and quenching. The consequence was no appreciable hardening effect due to the absence of Cu precipitation in either austenite or martensite after aging, degrading the alloy's desirable property profile. Conversely, Low N 17–4 showed no austenite in the as-built condition and a fully martensitic matrix after solution annealing. This variant had the desired aging response; a ∼ 140 HV 5 increase in hardness due to nanoscale Cu precipitation. Our findings describe the deleterious effects of compositional variations incurred during the LPBF process flow and how they can be overcome in 17–4 PH and similar steels.

Characterization of the microstructure, texture, and tensile behavior of additively manufactured Hastelloy X superalloy: Insights into heat treatment at 900 °C

This research aimed at the microstructural characterization and elucidation of room- and high-temperature tensile properties of additively manufactured Hastelloy X Ni-based superalloy heat-treated at 900 °C. The samples were fabricated via the laser powder bed fusion method utilizing two scan strategies known as island and meander types. The results indicated that the cellular structure embedded in the columnar grains of the as-built microstructure disappeared after applying the heat treatment, linking to the reduction in dislocation density while keeping the former morphology of the grains unchanged. However, the intensities of the Brass, Goss, Goss-Brass, and rotated Goss texture components were reduced, leading to the generation of more homogenous fibers in the heat-treated microstructure. Additionally, it caused the formation of a Mo-rich phase on the grain boundaries, which improved the room temperature's ultimate tensile strength. However, it was elucidated that the Mo-rich phase-induced void formation and intergranular cracking failure caused a slight decrease in hot ductility. Overall, the obtained results revealed that the heat-treated island samples showed superior hot tensile behavior than the meander sample due to having a larger grain size.

Laser Powder Bed Fusion Fabrication of a Novel Carbide-Free Bainitic Steel: The Possibilities and a Comparative Study with the Conventional Alloy

A newly developed medium-carbon carbide-free bainitic steel was fabricated for the first time utilizing the laser powder bed fusion (L-PBF) technique. Process parameters were optimized, and a high density of 99.8% was achieved. The impact of austempering heat treatment on the bainite morphology and transformation kinetics was investigated by high-resolution microstructural analysis (SEM, TEM, and EDS) and dilatometric analysis, and results were compared with conventionally produced counterparts. Faster kinetics and finer microstructures in the L-PBF specimens were found as a consequence of the as-built microstructure, characterized by fine grains and high dislocation density. However, a bimodal distribution of bainitic ferrite plate thickness (average value 60 nm and 200 nm, respectively) was found at prior melt pool boundaries resulting from carbon depletion at such sites.

Rapid Alloy Development Using Calphad Simulation and Powder Blends in Direct Energy Deposition

The ongoing commercialization of additive manufacturing (AM) has necessitated the need to tailor alloy chemistry as well as exploit AM process particularities such as freedom of design, print geometry and high cooling rates to meet functional application requirements. Alloys such as hot-work tool steels, including H11, are well suited for machining and tooling applications. In this work, the authors investigated and compared high-speed direct energy deposition with laser beam source (HS DED-LB/M) processability of a reference H11 alloy and its modified form (H11m). The modification of the alloy was intended to minimize the amount of retained austenite (RA) in as-built microstructure and reduce post-heat treatment steps. The investigative approach included Calphad simulation, rapid alloy blending (modified powder) and process parameter optimization to produce dense parts for microstructure characterization and mechanical properties testing. The results show that while H11 achieved a high relative density &gt; 99.85%, H11m still had cracks parallel to the building direction. The amount of RA was equally reduced from 4.08% in H11 to 1.23% in the H11m. H11 had a comparatively superior average microhardness (591 HV0.5) to H11m (561.5 HV0.5), which can be attributed to the more carbide presence. The martensitic strengthening effect between H11 and H11m can be described as similar.

Tailoring microstructure and mechanical properties of 17-4PH steel fabricated by wire-arc directed energy deposition via a combination of intrinsic and post-processing heat treatments

This paper examines the effect of intrinsic heat treatment, i.e., multiple transient heating from subsequent passes, and post-processing heat treatment on the microstructure and mechanical properties of 17–4PH stainless steel fabricated by wire-arc directed energy deposition. By carefully controlling the interpass temperature to remain below the martensite start (Ms) temperature, intrinsic heat treatment effectively triggers the formation of Cu-rich clusters and the reversion of austenite. This approach results in a concurrent enhancement in the ultimate tensile strength, increasing from 1036 MPa to 1128 MPa, and elongation, increasing from 13.2% to 18.5%, for the as-built part. During post-processing heat treatment, the microstructural response to direct aging treatment hinges on the initial microstructure induced by intrinsic heat treatment. Notably, direct aging treatment significantly enhances the hardness and ultimate tensile strength of the as-built part created at an interpass temperature surpassing the Ms temperature. Conversely, its influence on the mechanical properties of the as-built component, fabricated at an interpass temperature lower than the Ms temperature, remains minimal. Additionally, the application of a solution treatment effectively eradicates the inherent microstructural characteristics, regardless of the initial fabrication conditions. Nonetheless, the grain size of the solution-treated specimen is markedly influenced by the as-built microstructure. Ultimately, a judicious amalgamation of intrinsic and post-processing heat treatments yields an exceptional combination of properties, including high hardness (465 HV), ultimate tensile strength (1437 MPa), and elongation (14.5%). These results underscore the significance of a comprehensive consideration of intrinsic and post-processing heat treatments to tailor the microstructure and mechanical properties of 17–4PH steel fabricated by wire-arc directed energy deposition.

Influence of heat treatment on the tensile properties of Ti–15Mo additively manufactured by laser metal deposition

A bidirectional powder deposition strategy was employed to additively manufacture Ti–15Mo wt% using laser metal deposition. The as-built alloy was subsequently subject to post-fabrication heat treatment. Microstructural characterisation was conducted in the heat-treated state and also after uniaxial tensile deformation. X-ray diffraction, energy dispersive spectroscopy and scanning electron microscopy were employed in the heat-treated state. Electron backscatter diffraction was used in investigating the deformed microstructure. Columnar β grain refinement was achieved by fragmentation from a combined contribution from precipitated phases and deformation induced products. The three distinct microstructural zones, namely the fusion, remelted and heat affected zones, observed in each deposited layer of the as-built microstructure were retained after sub-β-solvus heat treatment but completely erased in the super-β-solvus microstructure. Accommodation of plastic deformation in β matrix was by a combination of slip and primary α′′ martensite which formed preferentially at grain boundaries. Elastic modulus decreased from 86.85 ± 0.45 GPa in the as-built alloy to 72.8 ± 0.65 GPa after heat treatment. Ultimate tensile strength of 1168± 1.12 MPa from the heat-treated sample represents only a marginal increase from that of the as-built sample of 1099± 2.3 MPa. This was accompanied by a small decrease in total elongation.

Origin of the enhanced pseudo-elasticity of additively manufactured Fe-17Mn-5Si-4Ni-10Cr-(V, C) shape memory alloy fabricated by laser powder bed fusion

This study investigated the origin of the enhanced pseudo-elasticity of additively manufactured vanadium carbide-containing Fe-based shape memory alloys. The aged samples with two different starting microstructures, as-built and solution-treated, showed completely different final microstructures following identical aging treatments. The sample aged directly from the as-built microstructure exhibited typical solidification structures, molten pools, and cellular structures with fine grain sizes inherited from the laser powder bed fusion process with a high cooling rate. In contrast, the sample aged following solution treatment revealed fully recrystallized grain structures with relatively larger grain sizes than the former. Despite having the same type of carbides, the directly aged sample had finer and denser precipitates than the sample aged following solution treatment. Additionally, compared to the sample aged following solution treatment, the directly aged sample exhibited a larger pseudo-elastic recovery strain. The precipitation behavior may have had a negligible impact on the pseudo-elastic behavior because the increase in the pseudo-elastic recovery strain following aging treatment was not significant for either sample. Besides, thermodynamic calculations predicted that the stability of the face-centered cubic (fcc)-γ phase would be increased by local elemental segregation at cell boundaries. Cell boundaries with high fcc-γ phase stability can act as sites that can apply back stress on the deformation-induced hcp-ε phase, thus promoting reverse motion of the Shockley partial dislocations or deformation-induced hcp-ε phase. Furthermore, the smaller grain size enhanced the stability of the fcc-γ phase.

Microstructural feature-driven machine learning for predicting mechanical tensile strength of laser powder bed fusion (L-PBF) additively manufactured Ti6Al4V alloy

The rapid solidification inherent in laser powder bed fusion (L-PBF) additive manufacturing (AM) introduces segregation phenomena and formation of non-equilibrium phases in duplex titanium alloy components, thereby impeding their suitability for high-reliability engineering applications. Consequently, heat treatment becomes indispensable for optimizing both the microstructure and mechanical properties to meet application requirements. This study aims to investigate the influence of varied annealing temperatures on the evolution of L-PBF-built Ti6Al4V alloy microstructure, subsequently elucidating their impact on tensile properties by analyzing of L-PBF process parameters, building orientations, and annealing temperatures. The findings reveal that annealing at 850 °C for 2 h facilitates the transformation of brittle martensite into a ductile lamellar (α + β) microstructure, thereby conferring excellent tensile properties upon the L-PBF-built Ti6Al4V alloy. Furthermore, to accurately predict the tensile strengths of the Ti6Al4V, we take into account the L-PBF process parameters and the as-built microstructures in a comprehensive manner, extracting the pertinent microstructural features. A machine learning (ML)-based model is built to facilitate accurate predictions. Accurate and reliable predictions are demonstrated by this model when applied to Ti6Al4V. This data-driven approach establishes a novel avenue for AM material property prediction and process parameter optimization.