Experimental-numerical Investigation of ⍺/β-phase formation within thin electron beam melted Ti-6Al-4V

Electron beam melting is a powder bed fusion process capable of manufacturing thin structural features. However, as the thickness of these features approaches typical microstructure grain sizes, it becomes vital to understand how the manufacturing process contributes to local crystallographic texture and anisotropy in micromechanical response. Therefore, this article investigates Ti-6Al-4V ⍺/β-phase formation within thin components using a variety of experimental and numerical approaches. Optical and scanning electron microscopy are used to determine through-thickness distributions of prior-β width ([top, middle, bottom]:[81.2 ± 44.2, 76.02 ± 30.4, 75.6 ± 31.2] μm), ⍺-lath thickness ([top, middle, bottom]:[1.0 ± 1.3, 1.3 ± 1.2, 1.4 ± 1.8] μm; average), and ⍺/β-phase fractions ([top, middle, bottom]:[0.87 ± 0.05, 0.82 ± 0.03, 0.88 ± 0.03]; average). Manufacturing process (i.e., "logfile") data is used within a layer-by-layer finite element "birth/death" model. This model is loosely coupled with the Kim-Kim-Suzuki phase field model and a CALPHAD thermodynamic database to predict ⍺-lath growth throughout the process. In general, good correlation is found between the experimental data and the predicted temperature history, ⍺-lath coarsening, and phase fraction. This indicates that these tools would be useful in predicting process-structure-properties-performance relationships for thin features.