Fatigue of additive manufactured Ti-6Al-4V, Part I: The effects of powder feedstock, manufacturing, and post-process conditions on the resulting microstructure and defects

Pegues, J. W.; Shao, S.; Shamsaei, N.; Sanaei, N.; Fatemi, A.; Warner, D. H.; Li, P.; Phan, N.

doi:10.1016/j.ijfatigue.2019.105358

Title: Fatigue of additive manufactured Ti-6Al-4V, Part I: The effects of powder feedstock, manufacturing, and post-process conditions on the resulting microstructure and defects

Journal Article · 02 November 2019 · International Journal of Fatigue

DOI: https://doi.org/10.1016/j.ijfatigue.2019.105358 · OSTI ID:1658677

Pegues, J. W. ^[1]; Shao, S. ^[1]; Shamsaei, N. ^[1]; Sanaei, N. ^[2]; Fatemi, A. ^[3]; Warner, D. H. ^[4]; Li, P. ^[4]; Phan, N. ^[5]

Auburn Univ., AL (United States)
Univ. of Toledo, OH (United States)
Univ. of Memphis, TN (United States)
Cornell Univ., Ithaca, NY (United States)
US Naval Air Systems Command (NAVAIR), Patuxent River, MD (United States)

Additive manufacturing provides an appealing means to process titanium alloy parts with new levels of conformability, complexity, and weight reduction. However, due to the heating/cooling rates and heat transfer associated with directed energy source material processing, the as-built AM parts contain unique material and microstructural features. In order to confidently manufacture fatigue critical additive manufactured (AM) Ti-6Al-4V parts, a better understanding of the interrelationships between powder feedstock, AM processes, structure of the processed parts, their resulting mechanical properties, and their performance under realistic loadings is necessary. Part I of this two-part collection focuses on the powder-process-structure relationships and how powder feedstock, manufacturing, and post-processing conditions can affect the microstructure and defect features that ultimately contribute to the fatigue performance of Ti-6Al-4V parts. The material and physical phenomena inherent to the AM process of Ti-6Al-4V are discussed in detail and related to the phase composition/structure, grain morphology, surface characteristics, defect size/distribution, and post-process treatments available for AM parts. This investigation is the foundation for the structure-performance relationships that will be covered in detail in Part II.

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Research Organization:: Louisiana State Univ., Baton Rouge, LA (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES); National Science Foundation (NSF); US Department of the Navy, Office of Naval Research (ONR)

Grant/Contract Number:: SC0019378; 1657195; N000141712035

OSTI ID:: 1658677

Alternate ID(s):: OSTI ID: 1776375; OSTI ID: 1867807

Journal Information:: International Journal of Fatigue, Vol. 132; ISSN 0142-1123

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 107 works

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Effect of Hot Isostatic Pressing Conditions and Cooling Rate on Microstructure and Properties of Ti–6Al–4V Alloy from Atomized Powder Xu, Lei; Guo, Ruipeng; Bai, Chunguang Journal of Materials Science & Technology, Vol. 30, Issue 12 https://doi.org/10.1016/j.jmst.2014.04.011	journal	December 2014
Effect of hot isostatic pressing procedure on performance of Ti6Al4V: Surface qualities, microstructure and mechanical properties Cai, Chao; Song, Bo; Xue, Pengju Journal of Alloys and Compounds, Vol. 686 https://doi.org/10.1016/j.jallcom.2016.05.280	journal	November 2016
Microstructural evolution and mechanical properties of powder metallurgy Ti–6Al–4V alloy based on heat response Guo, Ruipeng; Xu, Lei; Wu, Jie Materials Science and Engineering: A, Vol. 639 https://doi.org/10.1016/j.msea.2015.05.041	journal	July 2015
Effect of Hot-Isostatic-Pressing Parameters on the Microstructure and Properties of Powder Ti-6Al-4V Hot-Isostatically-Pressed Samples Zhang, K.; Mei, J.; Wain, N. Metallurgical and Materials Transactions A, Vol. 41, Issue 4 https://doi.org/10.1007/s11661-009-0149-y	journal	February 2010
The effect of processing on the 455°C tensile and fatigue behavior of boron-modified Ti–6Al–4V Chen, W.; Boehlert, C. J.; Payzant, E. A. International Journal of Fatigue, Vol. 32, Issue 3 https://doi.org/10.1016/j.ijfatigue.2009.04.013	journal	March 2010
The Effect of Hot Deformation Parameters on Microstructure Evolution of the α-Phase in Ti-6Al-4V Perumal, Bama; Rist, Martin A.; Gungor, Salih Metallurgical and Materials Transactions A, Vol. 47, Issue 8 https://doi.org/10.1007/s11661-016-3552-1	journal	May 2016
Flow behavior and globularization kinetics during hot working of Ti–6Al–4V with a colony alpha microstructure Semiatin, S. L.; Seetharaman, V.; Weiss, I. Materials Science and Engineering: A, Vol. 263, Issue 2 https://doi.org/10.1016/S0921-5093(98)01156-3	journal	May 1999
Process window for electron beam melting of Ti-6Al-4V Kirchner, A.; Klöden, B.; Luft, J. Powder Metallurgy, Vol. 58, Issue 4 https://doi.org/10.1179/0032589915Z.000000000244	journal	August 2015
Mechanical Properties of Ti-6Al-4V Fabricated by Electron Beam Melting Kirchner, Alexander; Klöden, Burghardt; Weißgärber, Thomas Key Engineering Materials, Vol. 704 https://doi.org/10.4028/www.scientific.net/KEM.704.235	journal	August 2016

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Fatigue Performance of Additively Manufactured Ti-6Al-4V: Surface Condition vs. Internal Defects Sun, Y. Y.; Lu, S. L.; Gulizia, S. JOM, Vol. 72, Issue 3 https://doi.org/10.1007/s11837-020-04025-7	journal	January 2020
Selective Laser Melting and Electron Beam Melting of Ti6Al4V for Orthopedic Applications: A Comparative Study on the Applied Building Direction Ginestra, Paola; Ferraro, Rosalba Monica; Zohar-Hauber, Keren Materials, Vol. 13, Issue 23 https://doi.org/10.3390/ma13235584	journal	December 2020

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