Complex Thermal Cycles Research Articles

Adaptation of a Model Spike Aptamer for Isothermal Amplification-Based Sensing

Isothermal amplification (IA) techniques like rolling circle amplification (RCA) and loop-mediated isothermal amplification (LAMP) have gained significant attention in recent years due to their ability to rapidly amplify DNA or RNA targets at a constant temperature without the need for complex thermal cycling equipment. Such technologies, combined with colorimetric systems rendering visual confirmation of the amplification event, are ideal for the development of point-of-need detection methods suitable for field settings where access to specialized laboratory equipment is limited. The utility of these technologies, thus far limited to DNA and RNA targets, could be broadened to a wide range of targets by using aptamers. Composed of DNA or RNA themselves, aptamers can bind to substances, including proteins, metabolites, and inorganic substances. Their nucleic acid nature can potentially allow them to serve as a bridge, extending the reach of DNA/RNA-centric technologies to the broader molecular world. Indeed, the change in aptamer conformation occurring during ligand interaction can be used to elaborate ligand-responding RCA or LAMP templates. By using an existing aptamer targeting SARS-CoV-2 Spike protein as a model, we explored the possibility of establishing ligand-responsive IA systems. Our study used aptamers with simple sequence modifications as templates in LAMP assays and hyperbranched RCA (HRCA) by exploiting the dynamic nature of the model aptamer to trigger these IA systems. Importantly, our work uniquely demonstrates that this aptamer’s dynamic response to ligand binding can regulate both RCA and LAMP processes. This novel approach of using aptamer conformational changes to trigger LAMP paves the way for new aptamer-based detection assays. Our system detects 50 nM of Spike protein, with LAMP occurring within 30 min in the presence of Spike. The colorimetric readout showed clear results, allowing for the detection of Spike protein presence.

Microstructure and Mechanical Properties of Bimetallic Structure Fabricated through Wire Plus Arc Additive Manufacturing

This study investigates the fabrication and mechanical assessment of bimetallic structure (BMS) wall using wire plus arc additive manufacturing (WAAM) technology, employing stainless steel (SS) 304 and SS 308L SS filler wire. The usage of BMS is promoted due to the limitation faced during dissimilar welding of the SS grades. The high or improper melting of the interface will lead to elemental segregation, leading to structural failure. Producing seamless BMS plates will be an ideal replacement for dissimilarly welded joints. Notably, 308L SS demonstrates superior mechanical properties compared to 304 SS, exhibiting impressive tensile strength (TS) and exceptional ductility. BMS, constructed with 308L filler wire, closely matches these better mechanical attributes, making it an attractive choice for applications prioritizing mechanical performance. Furthermore, when compared to WAAM‐processed SS 304, BMS consistently outperforms in terms of TS while retaining remarkable ductility. This is due to the variation in the microstructure caused by complex thermal cycles. Hence, this research provides valuable insights into manufacturing and characterization of BMS, emphasizing the potential of WAAM‐processed BMS (SS 304/SS 308L) in engineering applications demanding superior mechanical properties while replacing dissimilar joints in the fields of aerospace, aviation, automobile, and power generation industries.

Investigation of the microstructural characteristics of laser-cladded Ti6Al4V titanium alloy and its corrosion behavior in simulated body fluid

Laser cladding technology has a wide range of potential industrial applications in the surface strengthening, repair and reuse of orthopedic implants. By employing this technique to conduct same-material surface restoration and enhancement on titanium alloys, it demonstrates significant developmental potential. However, the microstructure of laser additively manufactured titanium alloy differs significantly from that of traditional titanium alloys, which affects its corrosion resistance in human body fluids. To compare the corrosion resistance differences between the cladding layer and the substrate, this study investigates the microstructure of multi-pass laser cladding Ti6Al4V (TC4) titanium alloy and analyzes the corrosion morphology and corrosion products of the cladding layer in simulated body fluids (SBF). By comparing the electrochemical corrosion behavior of laser cladding with that of traditionally manufactured TC4, this research reveals the differences in corrosion resistance between the two titanium alloys. The research demonstrates that the microstructure of cladding primarily consists of prior-β grains and continuous grain boundary α phase, along with a complex basketweave structure composed of fine acicular α phase and lamellar α phase. Additionally, due to the complex thermal cycling process, the acicular α' colonies within the prior-β grains. These features enhance the cladding layer’s resistance to plastic deformation and increase microhardness, though with some uneven distribution. Interestingly, the TC4 cladding layer forms a porous passivation layer after corrosion, primarily composed of a TiO2 passivation film and deposits of hydroxyapatite and other phosphates. Due to the lower β-phase content, finer grains with higher energy states, and a greater proportion of high-angle grain boundaries (HAGBs) in the cladding layer, it exhibits higher electrochemical activity. As a result of these microstructural differences, the corrosion resistance of the TC4 cladding layer in SBF is inferior to that of TC4 manufactured using traditional techniques.

Achieving low-porosity AlSi10Mg cladding layers for the additive repair of aluminum alloy parts by directed energy deposition

Directed Energy Deposition (DED) has broad application prospects for repairing damaged aluminum alloy parts such as piston aero-engine casing. However, due to the low laser absorptivity and the complex thermal cycle process, it is challenging to obtain aluminum alloy cladding layers with high-quality morphology and low-porosity by DED method. In this work, a series of individual stages of DED process are studied during single-tracks overlapping and layers stacking. Correspondingly, the within layer scanning strategy, inter-layer stacking strategy, and process parameters are examined carefully. Using the proposed DED processing flow that combines substrate preheating with intermittent process, the deposited layers without balling and collapse are successfully achieved. Furtherly, the bi-directional scanning strategy for single-tracks overlapping within layer is proposed to compensate the thickness nonuniformity caused by heat accumulation. The inter defects identified as “lack of fusion” and “gas pores” are observed in the cladding layers with uniform surface. By analyzing the pore formation mechanism and considering the energy distribution and re-melting, the multi-layer offset stacking strategy is proposed to inhibit the porosity to 0.25 %. Combined with the optimized process parameters, the porosity is reduced up to 0.09 %, ensuring the density of the DED deposition coating. This work provides new pathway and direct guidance for fabricating high-quality AlSi10Mg cladding layers during the DED repairing of valuable aluminum alloy parts.

Influence of phase transformation coefficient on thermomechanical modeling of laser powder bed fusion for maraging 300 steel

Manufacturing maraging steel components using laser-based powder bed fusion (LPBF) presents an attractive proposition for industries due to the material's combination of mechanical properties such as hardness, wear resistance, toughness and the capability to produce parts with complex geometries and high precision. Despite these advantages, the LPBF process induces defects such as distortion and residual stress associated with the complex thermal cycles, compromising final part quality. Numerical simulations have been developed to predict these defects. However, LPBF simulations remain challenging due to the complexity of the process and the substantial computational resources required. For maraging steel, for example, the occurrence of phase transformation promotes compressive stress that interferes in results and makes simulations inaccurate. This research aims to simulate a geometry with a circular inner channel and investigate distortion, volume fraction of martensite and equivalent stress results. Modeling was performed by varying phase transformation rate parameters to assess the impact of transformations on simulation outcomes. Results showed minimal impact of these parameters on distortions and equivalent stress. Equivalent stress results were compared with literature findings, while distortion results were validated against experimental data to validate the accuracy of the model.

Development and manufacturing of beryllium-armoring ITER enhanced heat flux FW toward series production in China

ITER’s enhanced heat flux (EHF) first wall (FW) provides thermal shielding to the other components behind it and limits its plasma boundary, consequently bearing high surface heat loads up to 4.7 MW m−2. China developed the EHF FW technologies in steady stages by making small mock-ups, semi-prototypes and a full-scale prototype (FSP), working toward series production at the Southwestern Institute of Physics. All the key technologies for bimetallic diffusion bonding, welding and assembly have been fully qualified. The Be armor tile size effects on thermal-fatigue performance have been evaluated using a pulsed high heat flux test with an EMS-400 electron beam facility. It was found that both the Be/CuCrZr bonding and its thermal-fatigue life are highly dependent on the tile size, and 12 × 12 mm2 Be tiles are acceptable for the required performance, either as individual tiles or in castellation by cutting larger ones. Small-scale mock-ups with such Be tiles survived 16 000 thermal cycles at 4.7 MW m−2, while EHF FW fingers with 16 × 16 mm2 Be tiles demonstrated unstable performance. In contrast, only BE tiles larger than 24 × 12 mm2 showed reliable diffusion bonding with the CuCrZr heat sink by hot isostatic pressing and consequently should be castellated into smaller ones. The manufacturing of the FSP finger goes through complex thermal cycles, using CuCrZr alloys in age-strengthening plus cold-rolling states, enabling it to maintain its tensile strength to the level of 285 MPa and its mean grain size less than 100 µm. The pipe welding for finger pairing and its assembly with the central beam are demonstrated, including enabling welding to be carried out twice for repair in a narrow space. The FSP showed good finger alignment, dimensional control and reliable vacuum tightness without any blockage of cooling channels.

The Microstructure characteristic and Its influence on the stray grains of Nickel-based single crystal superalloys prepared by Laser directed energy deposition

The microstructure adjustment and the stray grains inhibition are important for the preparation of Nickel-based single crystal (SX) superalloys by laser directed energy deposition (L-DED). In this work, the single channel monolayer and single channel five-layers DD6 SX superalloys have been prepared by L-DED. The macroscopic simulations in the deposition processing and multiscale characterizations of deposition structure were used to analyze the formation and evolution mechanisms of unique precipitations and stray grains. Results shows that the larger laser power and higher powder feed rate have a positive impact on the epitaxial growth of columnar dendrite and the elimination of stray grains. The residual stress caused by the complex thermal cycles is not the direct reason that induce the formation of SGs, but the rapid movement of dislocations result in the formation of sub-grain boundary. According to the columnar transition to equiaxed theory (CET), temperature field simulation and analysis of element segregation behaviors, the element segregation results in the unique microstructure, include petal-shaped γ/γ′ eutectic and demarcation band with a thickness of a single γ/γ′ eutectic. Besides, the geometric size of γ/γ′ eutectic decrease with respect to the deposition height. With the change of height at deposition region, dendritic orientation deviations affect the uniformity of element segregation, resulting in variations in γ′ phase and γ/γ′ eutectic dimensions between dendritic core and the inter-dendrite zone at the microscopic level and manifesting as grain boundaries at the mesoscale. At the same time, the formation mechanisms of carbide and adjacent γ/γ′ eutectic leads to the misorientations between the dendrite core and the inter-dendrite zone, which also appears as stray grains at the mesoscopic scale.

Aging heat treatment design for Haynes 282 made by wire-feed additive manufacturing using high-throughput experiments and interpretable machine learning

ABSTRACT Wire-feed additive manufacturing (WFAM) produces superalloys with complex thermal cycles and unique microstructures, often requiring optimized heat treatments. To address this challenge, we present a hybrid approach that combines high-throughput experiments, precipitation simulation, and machine learning to design effective aging conditions for the WFAM Haynes 282 superalloy. Our results demonstrate that the γ’ radius is the critical microstructural feature for strengthening Haynes 282 during post-heat treatment compared with the matrix composition and γ’ volume fraction. New aging conditions at 770°C for 50 hours and 730°C for 200 hours were discovered based on the machine learning model and were applied to enhance yield strength, bringing it on par with the wrought counterpart. This approach has significant implications for future AM alloy production, enabling more efficient and effective heat treatment design to achieve desired properties.

Microstructure and finite element simulation (tensile test) of stainless steel wall produced by wire and arc additive manufacturing

This investigation aims to provide functional insight into simulating the tensile behavior of additively fabricated stainless steel 316L plate using finite element simulation and the Johnson-Cook model of ductile damage. The stainless steel 316L plate is fabricated through wire arc additive manufacturing using ideal process variables selected through numerous trial and error experiments. There is a significant increase in the strength of additively fabricated specimens (517.9 MPa) than wrought alloy samples (491.3 MPa). Finite element simulation was used successfully to simulate the tensile test, and the outcomes were predicted with an error percentage of less than 1. The significant enhancement in the strength is due to variations in the microstructure such as dendritic growth, phase changes influenced by complex thermal cycle, and residual δ-ferrite in wire arc additive manufacturing plate. The presence of residual δ-ferrite is also clear through the evaluation of ferrite number as it varied from bottom to top in the range of 5.2–4.9.

Microstructure, mechanical properties, and corrosion behaviour of wire arc additive manufactured martensitic stainless steel 410 for pressure vessel applications

High-strength martensitic stainless steel 410 (MSS 410) was successfully fabricated without defects via wire arc additive manufacturing (WAAM). The microstructural features, mechanical properties, and corrosion performance of WAAM-processed MSS 410 were examined. Microstructural analysis revealed the existence of equiaxed and coarse columnar dendrites and the formation of residual delta-ferrite and retained-austenite (RA) was confirmed within the martensitic matrix. The fraction of residual ferrite and RA varied along the building direction due to complex thermal cycles. Uni-axial tensile results exhibited anisotropic behavior and are related to layered microstructure. Microhardness values varied from bottom to top (384–460 HV). Ductile mode of failure was noticed, and the existence of RA influences the ductility. The corrosion behaviour of the WAAM 410 specimens in 3.5% NaCl solution was considerably acceptable, and the corrosion rate ranged between 0.05 and 1.37 mpy. This shall be attributed to the absence of defects, microstructural features, and ferrite fraction in the WAAM 410 samples. The mechanical properties and corrosion behaviour of the WAAM 410 were comparable to the wrought grade and are suitable for pressure vessel applications with adequate corrosion resistance.

Microstructure, hardness, and electrical resistivity of Al-Cu alloy fabricated via wire arc additive manufacturing

Additive manufacturing (AM) techniques allow for greater design freedom than is possible with conventional manufacturing processes. Components fabricated via AM can be compact and more potent for electrical applications. This study used cold metal transfer (CMT) based wire arc additive manufacturing (WAAM) to build the WAAM 2319 wall. The microstructure is mainly composed of equiaxed and columnar dendrites along with a small fraction of pores. Precipitated θ phases formed due to complex thermal cycles during WAAM. The hardness of the WAAM 2319 alloy ranged between 68 HV0.2 to 86 HV0.2. The electrical resistivity of WAAM 2319 was 6.72±0.23 µΩ.cm resulting in the reduced conductivity of 25.66±1.10%IACS compared to the wrought AA2219 alloy having 30%IACS. The decrease in electrical conductivity is attributed to the presence of coarse precipitates along with dendritic microstructure and copper solute concentration. Thus, WAAM-processed Al-Cu alloys can be used for future electrical applications.

Thermal analysis and microstructure evolution of TiC/Ti6Al4V functionally graded material by direct energy deposition

Metal/ceramic functionally graded materials (FGMs) have attracted significant attention due to their ability to combine the unique mechanical properties of metals with the high-temperature resistance of ceramics while mitigating the thermal stresses arising from the differences in their thermal expansion coefficients. In this study, the directed energy deposition (DED) technology is applied to manufacturing TiC/Ti6Al4V FGMs with TiC contenting up to 50 wt%. However, the variations in composition gradients and the complex thermal cycling processes lead to difficulties in the microstructure evolution and control. Therefore, a combined approach involving finite element (FE) simulations and experiments was employed to investigate the mechanisms underlying microstructural transformations under various gradient thermal cycles. The results showed that the morphology of TiC in the FGM from top to bottom is as follows: coarse dendritic TiC + unmelted TiC, granular primary TiC + underdeveloped dendritic TiC, chain-like eutectic TiC + granular eutectic TiC. Meanwhile, both α-Ti and β-Ti exhibited equiaxed transformation, with their sizes decreasing continuously with the gradient. This is due to the strong orientation relationship between TiC particles and the titanium matrix, allowing α-Ti and β-Ti to form non-uniform nucleation within the TiC phase. In addition, the chain-like eutectic TiC and dendritic primary TiC showed a certain degree of fragmentation and granulation after undergoing thermal cycling. The microstructural evolution mechanism in different gradient regions during the DED process under the coupling effect of thermal cycling and ceramic composition was clarified by combining the FE simulation results. The specimen at the bottom of FGMs exhibits strong and ductile (tensile strength: 1296 MPa, elongation: 7.17 %), which are mainly attributed to the Hall Petch strength and solid solution strengthening. The brittle phase of dendritic TiC and unmelted TiC under high gradients leads to decreased tensile properties.

Residual Stresses in a Wire and Arc-Directed Energy-Deposited Al–6Cu–Mn (ER2319) Alloy Determined by Energy-Dispersive High-Energy X-ray Diffraction

In order to enable and promote the adoption of novel material processing technologies, a comprehensive understanding of the residual stresses present in structural components is required. The intrinsically high energy input and complex thermal cycle during arc-based additive manufacturing typically translate into non-negligible residual stresses. This study focuses on the quantitative evaluation of residual stresses in an Al–6Cu–Mn alloy fabricated by wire and arc-directed energy deposition. Thin, single-track aluminum specimens that differ in their respective height are investigated by means of energy-dispersive high-energy X-ray diffraction. The aim is to assess the build-up of stresses upon consecutive layer deposition. Stresses are evaluated along the specimen build direction as well as with respect to the lateral position within the component. The residual stress evolution suggests that the most critical region of the specimen is close to the substrate, where high tensile stresses close to the material’s yield strength prevail. The presence of these stresses is due to the most pronounced thermal gradients and mechanical constraints in this region.

Optimization of a Reverse-Brayton cycle with inter-cooling and regeneration

A Reverse-Brayton cycle represented by the B787 electrical driven environmental control system is used as the analysis object, including the thermodynamic process of two-stage compression, intercooling, and regeneration. An analytical expression for the thermodynamic performance of the cycle is derived based on the endoreversible thermodynamic analysis model (ETM). Combined with a genetic algorithm, an ETM-based optimization approach (ETM-OA) is proposed. Using this method, it is found that the coefficient of performance is increased by 34.1 % and 48.4 % under two typical flight conditions, respectively, and the corresponding system entropy generation number is reduced by 30.2 % and 51.1 %, respectively. Both ETM-OA and entropy generation analysis show that the electric supercharging module, secondary heat exchanger, and air cycle machine are key components of the system. This study provides a convenient method for obtaining the thermal power conversion mechanism of complex thermal cycles and conducting optimization analysis.

Microstructure and mechanical properties of Mg-Gd-Y-Zn-Zr alloy fabricated by cold metal transfer wire arc additive manufacturing

Wire arc additive manufacturing (WAAM) offers significant advantages in rapid manufacturing of complex integral parts. In this study, Mg-Gd-Y-Zn-Zr alloy deposited walls were fabricated by cold metal transfer (CMT) based WAAM. The interface bonding relationship between the additive zone and the substrate was studied, as well as the effect of the microstructure of the additive zone on the mechanical properties. The precipitated phase Mg24Y5 mainly distributed at the grain boundary was found in the additive zone of deposited walls, nano-scale contact interface and diffusion bonding interface were formed between β-Mg24Y5 and α-Mg (OR: [001]β-Mg24Y5//[10 1‾ 0]α-Mg), and a portion of the 18 R-LPSO phase to 14H-LPSO phase transition occurred in the substrate zone. In each layer of deposited metal, the bottom zone had a higher cooling rate than the top zone, which led to the supersaturation of rare earth elements. The precipitated phases between different deposition layers showed a decreasing trend from the bottom zone to the top zone due to the complex multiple thermal cycles in the additive manufacturing process. Compared with the cast Mg-Gd-Y-Zn-Zr alloy, the mechanical properties (UTS, YS and EL) of the Mg-Gd-Y-Zn-Zr alloy fabricated by WAAM were significantly increased. The ultimate tensile strength of the deposited walls along the travel direction was 227.27 MPa, and the elongation was 8.08 %.

Ultrasensitive detection porcine transmissible gastroenteritis virus based on the dual-photoelectrode photofuel cell with in-situ isothermal amplification

Loop-mediated isothermal amplification (LAMP) as a nucleic acid detection technology has many advantages than conventional polymerase chain reaction in terms of sensitivity, specificity, and equipment requirements. And combining photocatalytic fuel cell (PFC) power density readout with high sensitivity, we developed a LAMP-based dual-photoelectrode photocatalytic fuel cell based self-powered biosensors (LAMP PFC-SPBs) for the ultra-sensitive detection of transmissible gastroenteritis virus (TGEV). In this sensor, the specially designed primers were immobilized on the photosensitive material CdS-modified sensing substrate with a distinct electrochemical signal and amplified TGEV within 1 h. A wide detection range of the LAMP PFC-SPBs was demonstrated, ranging from 0.075 fg μL−1 to 7.5 ng μL−1, with a lower detection limit of 0.025 fg μL−1. In-situ LAMP PFC-SPBS had great merits in simplicity (no complex thermal cycles, no need for expensive instruments), sensitivity, specificity, and provides a new perspective on the combination of nucleic acid amplification and electrochemistry.

Grain interactions under thermo-mechanical loads investigated with coupled crystal plasticity simulations and high-energy X-ray diffraction microscopy

Nickel (Ni)-based superalloys are used for safety-critical components in the aerospace industry because of their high strength at elevated temperatures. These materials are subjected to complex thermal and mechanical cycling due to service conditions, which leads to thermo-mechanical fatigue (TMF) failure. The failure mechanisms associated with TMF are dependent on microstructural characteristics and loading parameters, such as temperature, strain range, and strain-temperature phasing, requiring a large set of experimental test matrices to study TMF failure. One means to reduce the necessity of extensive and exhaustive testing for material qualification is with model-based approaches. In this work, to study the complexities of micromechanical TMF damage, a temperature-dependent, dislocation density-based crystal plasticity model for a Ni-based superalloy is generated with uncertainty quantification. The capabilities of the model's temperature dependency are examined via direct instantiation and comparison to a high-energy X-ray diffraction microscopy (HEDM) experiment under coupled thermal and mechanical loads. Unique loading states throughout the experiment are investigated with both crystal plasticity predictions and HEDM results to study early indicators of TMF damage mechanisms at the grain scale. Via a crystal plasticity-based failure metric that can predict likely sites for crack initiation, regions of extreme values indicate the spatial location of microstructural damage, while showing correlation with high strain gradients. The results also indicate that the extreme value of thermo-mechanical damage accumulation is influenced by the surrounding grains characteristics including slip system activity, lattice curvature, and neighboring grain compatibility interactions, quantified via a grain interaction strength-to-stiffness ratio orthogonal to the grain boundary.

Microstructure and Mechanical Properties of NiTi Alloy Prepared by Double-Wire + Arc Additive Manufacturing Plus In Situ Heat Treatment.

In this study, NiTi shape memory alloy was prepared by double-wire + arc additive manufacturing plus in situ heat treatment using TA1 and ER-Ni welding wires as the raw materials. The results show that the microstructural evolution from the bottom to top is NiTi2 + NiTi → NiTi + Ni3Ti + Ni4Ti3 → NiTi + Ni4Ti3 + Ni3Ti2 + Ni3Ti + α-Ti. Complex thermal cycles led to the precipitation of Ni3Ti, which improves the hardness of the matrix (B2), and the average hardness value of the top region reaches 550.7 HV0.2. The fracture stress is 2075 ± 138.4 MPa and the fracture strain is 11.2 ± 1.27%. The sample shows 7.02% residual strain and 5.87% reversible strain after 15 cycles, and the stress hysteresis decreases with an increase in cyclic strain.

Effect of multiple thermal cycling on the microstructure and microhardness of Inconel 625 by high-speed laser cladding

Establishing the relationship between thermal cycling and the induced evolution of microstructures and cladding layer properties is crucial to achieving microstructural and performance control, given the complexity involved in high-speed laser cladding process. We hereby report our new findings from laser cladding of Inconel 625 on Q245R steel substrate using a high-speed laser cladding technique. The microstructure evolution and microhardness variations in the first cladding track with different thermal cycles were examined by XRD, SEM, EBSD, TEM, and microhardness tests in detail. Numerical simulation was also conducted to characteristically illustrate the complex thermal cycles during the laser cladding process. Our work revealed that the first six thermal cycles resulted in significant variations of microstructure in the laser cladding layers. The dislocation density and low angle grain boundaries (LAGBs) of the first cladding track decreased after two thermal cycles due to the high peak temperature (above 1000 °C) of thermal cycles and subsequently increased when subjected to further thermal cycles with low peak temperature (below 500 °C). The microhardness value increased from 220 HV0.2 to 320 HV0.2, mainly caused by the formation of precipitated phase during the first four thermal cycles, and through by the enhancement of dislocations after six thermal cycles.

Characterisation of additively manufactured titanium wall: Mechanical and microstructural aspects

Titanium is as strong as steel with less density. Therefore, titanium and its alloys are used in several engineering applications. The primary benefits of using titanium alloys in the production of high-performance components include their light weight, superior tensile strength and exceptional corrosion resistance. Titanium alloys have the capacity to keep their characteristics even at high temperatures. Because of their low density and capacity to withstand temperature extremes, these alloys are mostly utilised in airplanes, spacecraft and missiles. Many of the initiatives to save costs in the production of titanium components are based on additive manufacturing. This study aims to provide preliminary insight into the microstructural and mechanical behaviour of commercially pure grade-2 titanium (CP-Gr-2-Ti) structured wall fabricated by gas tungsten arc welding assisted layer-by-layer manufacturing (GTAW-assisted-LM). Ideal process variables were selected through the trial-and-error method. The vacuum chamber was used during fabrication to ensure that the wall was free of contamination. The anisotropy in the LM processed wall is studied with different orientations of tensile samples. The variation in the microstructure observed in LM processed wall was due to varying complex thermal cycles. The phase texture and grain nature of the wall was studied using pole figures and inverse pole figures. The LM-processed wall exhibits better mechanical properties compared to wrought alloys. The fractography revealed several morphologies indicating that the fractured samples were ductile. Hence, a piece of first-hand information and experience is gained in this research work.