Competing roles of microstructure and defects on the mechanical properties of laser-powder bed fused Ti-6Al-2Sn-4Zr-2Mo alloy
Harish Chandra Kaushik, Sajad Shakerin, Mahdi Habibnejad Korayem, Mohsen Mohammadi, Amir Hadadzadeh
Abstract
Abstract Using different volumetric energy densities ( $${E}_{\text{v}}$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:msub> <mml:mi>E</mml:mi> <mml:mtext>v</mml:mtext> </mml:msub> </mml:math> ), the microstructure, texture, and defect evolution in laser-powder bed fused (PBF-LB/M) Ti-6Al-2Sn-4Zr-2Mo (Ti-6242) alloy is studied. PBF-LB/M Ti-6242 rods were manufactured using different $${E}_{\text{v}}$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:msub> <mml:mi>E</mml:mi> <mml:mtext>v</mml:mtext> </mml:msub> </mml:math> ranging from 41.67 to 66.67 J/mm 3 . The $${E}_{\text{v}}$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:msub> <mml:mi>E</mml:mi> <mml:mtext>v</mml:mtext> </mml:msub> </mml:math> is varied by setting the scan speed to 1000 mm/s, 1200 mm/s, 1400 mm/s, and 1600 mm/s. The mechanical properties (yield strength, tensile strength, and strain at fracture) were then studied under quasi-static loading conditions. It is observed that the strength of the sample printed using the lowest $${E}_{\text{v}}$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:msub> <mml:mi>E</mml:mi> <mml:mtext>v</mml:mtext> </mml:msub> </mml:math> is lower than the other conditions due to the formation of the lack of fusion defects. In addition, the sample printed with the highest $${E}_{\text{v}}$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:msub> <mml:mi>E</mml:mi> <mml:mtext>v</mml:mtext> </mml:msub> </mml:math> consists of redeposited process by-products that result in the lowest ductility. The microstructure and texture of the samples were studied using electron backscatter diffraction. The results show that microstructural features including α′ lath width, dislocation density, and lath orientation (texture) were almost identical under different $${E}_{\text{v}}$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:msub> <mml:mi>E</mml:mi> <mml:mtext>v</mml:mtext> </mml:msub> </mml:math> . Therefore, the variations in mechanical properties may not controlled completely by the microstructure. The defect analysis is conducted employing X-ray computed tomography. The defect characteristics change from keyhole to lack of fusion by varying the $${E}_{\text{v}}$$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:msub> <mml:mi>E</mml:mi> <mml:mtext>v</mml:mtext> </mml:msub> </mml:math> . The volume fraction of defects in the samples is in the range of 0.0005–0.007%, which seems to be negligible. However, the fractography analysis shows the dominance of defects in controlling the mechanical properties. This study proves the sensitivity of PBF-LB/M Ti-6242 to defects as the mechanical properties were defect-driven rather than microstructure-driven.