Hybrid electron beam powder bed fusion additive manufacturing of Ti–6Al–4V: processing, microstructure, and mechanical properties

R. Tosi*, E. Muzangaza, X. P. Tan, D. Wimpenny, M. M. Attallah

*Corresponding author for this work

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Abstract

Processing, microstructure, and mechanical properties of the hybrid electron beam powder bed fusion (E-PBF) additive manufacturing of Ti–6Al–4V have been investigated. We explore the possibility of integrating the substrate as a part of the final component as a repair, integrated, or consolidated part. Various starting plate surface conditions are used to understand the joining behavior and their microstructural properties in the bonding region between the plate and initial deposited layers. It is found that mechanical failures mainly occur within the substrate region due to the dominant plastic strains localized in the weaker Ti–6Al–4V substrate. The hybrid concept is successfully proven with satisfactory bonding performance between the E-PBF build and substrate. This investigation improves the practice of using the hybrid E-PBF additive manufacturing technique and provides basic understanding to this approach.

Original languageEnglish
Pages (from-to)927-941
Number of pages15
JournalMetallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
Volume53
Issue number3
DOIs
Publication statusPublished - 13 Jan 2022

Bibliographical note

Funding Information:
The authors acknowledge financial support from AMAZE (Additive Manufacturing Aiming towards Zero Waste and Efficient Production of High-Tech Metal Products) project funded by the 7th Framework Programme of the European Commission (Contract FP7-2012-NMP-ICT-FoF-313781). The Manufacturing Technology Centre (MTC) for the use of their facilities and technical and financial support provided along the project. RT, DW conceived the project. EM generated the machine files and performed the builds. RT, DW, EM, and MA reviewed and technically supported the project along its evolution. RT performed optical imaging and led mechanical testing. RT, EM, and XPT led the results discussion and interpretation. RT, EM, and XPT paper writing. On behalf of all authors, the corresponding author states that there is no conflict of interest.

Funding Information:
The authors acknowledge financial support from AMAZE (Additive Manufacturing Aiming towards Zero Waste and Efficient Production of High-Tech Metal Products) project funded by the 7th Framework Programme of the European Commission (Contract FP7-2012-NMP-ICT-FoF-313781). The Manufacturing Technology Centre (MTC) for the use of their facilities and technical and financial support provided along the project.

Publisher Copyright:
© 2022, The Author(s).

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Metals and Alloys

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