Laser powder bed fusion of a β titanium alloy: Microstructural development, post-processing, and mechanical behaviour

β-Titanium alloys demonstrate unique properties, especially their low elastic modulus, good balance of strength and ductility, and strong heat treatment response. In this study, pre-alloyed powder of a β-Ti-alloy Ti–34Nb–13Ta–5Zr-0.3O (TNTZO) was processed using Laser Powder Bed Fusion (LPBF). Dense builds that demonstrate a full β microstructure with limited texture were achieved following process optimisation, with an elastic modulus of 56.5 GPa, tensile strength of 756 MPa, elongation-to-failure of 20 %, and recoverable strain of 1.3 %. Due to the high oxygen content, the β→α′′ deformation induced transformation was supressed, which resulted in a typical elastic-plastic stress-strain behaviour unlike the double-yielding behaviour typically experienced in superelastic Ti-alloys. The alloy was particularly sensitive to ageing heat treatments that resulted in needle α-precipitation, with tensile strengths exceeding 950 MPa, elastic modulus of ∼80 GPa, and recoverable strain of 1.5 %, yet at the expense of a reduced elongation-to-failure of 9 %. Transmission electron microscopy and electron backscattered diffraction investigations revealed the deformation mechanism was slip-dominated with no trace of twinning or stress induced phase transformation.