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Production of Single Tracks of Ti-6Al-4V by Directed Energy Deposition to Determine the Layer Thickness for Multilayer Deposition
Published on: March 13, 2018
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Wire-Based Additive Manufacturing of Ti-6Al-4V Using Electron Beam Technique
Florian Pixner1, Fernando Warchomicka1, Patrick Peter1,2
1Institute of Materials Science, Joining and Forming, Graz University of Technology, Kopernikusgasse 24, 8010 Graz, Austria.
Materials (Basel, Switzerland)
|July 30, 2020
Summary
Electron beam freeform fabrication enables robust building of Ti-6Al-4V titanium alloy. Optimized parameters yield uniform layers and structures, with heat treatment improving ductility and reducing residual stress.
Area of Science:
- Materials Science
- Additive Manufacturing
- Metallurgy
Background:
- Electron beam freeform fabrication (EBFF) is a wire-feed additive manufacturing technique.
- Vacuum conditions in EBFF offer superior atmospheric shielding, crucial for reactive materials.
- Ti-6Al-4V is a widely used α + β-titanium alloy with applications in aerospace and biomedical fields.
Purpose of the Study:
- To determine optimal process parameters for robust electron beam freeform fabrication of Ti-6Al-4V.
- To investigate the correlation between process parameters, bead dimensions, and dilution.
- To characterize the microstructure, mechanical properties, and residual stresses of the fabricated alloy.
Main Methods:
- Utilized wire-feed electron beam freeform fabrication.
- Optimized process parameters for single bead deposition and layer stacking.
- Employed microscopy for microstructural analysis.
- Conducted tensile testing and hardness measurements.
- Measured residual stresses using energy dispersive X-ray diffraction.
Main Results:
- Achieved a 70%-75% bead overlap for uniform layer height and linear build-up rate.
- Microstructure revealed columnar prior β-grains with scattered pores.
- As-fabricated material showed a hardness of 334 HV, UTS of 953 MPa, and elongation of 4.5%.
- Stress relief heat treatment increased elongation to 9.5% while reducing UTS to 881 MPa.
- As-deposited residual stresses ranged from 200-450 MPa (tensile), reduced to near zero post-treatment.
Conclusions:
- Established suitable process parameters for EBFF of Ti-6Al-4V, enabling robust fabrication of simple structures.
- Microstructural and mechanical properties were characterized, showing potential for engineering applications.
- Stress relief heat treatment is effective in mitigating residual stresses and enhancing ductility.
