Process-structure-property considerations for wire-based directed energy deposition of Ti-6Al-4V

Journal Article · 31 August 2023 · Materials Characterization

DOI: https://doi.org/10.1016/j.matchar.2023.113280 · OSTI ID:2311519

Sims, Hannah ^[1]; Pegues, Jonathan Wesley ^[1]; Whetten, Shaun Ross ^[1]; Kustas, Andrew B. ^[1]; Moore, David G. ^[1]

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1. Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Directed energy deposition (DED) is an attractive additive manufacturing (AM) process for large structural components. The rapid solidification and layer-by-layer process associated with DED results in non-ideal microstructures, such as large grains with strong crystallographic textures. These non-ideal microstructures can lead to severe anisotropy in the mechanical properties. Despite these challenges, DED has been identified as a potential solution for the manufacturing of near net shape Ti-6Al-4V preforms, replacing lost casting and forging capabilities. Two popular wire-based directed energy deposition (W-DED) processes were considered for the manufacturing of Ti-6Al-4V with assessments on their respective metallurgical and mechanical properties, as compared to a conventionally processed material. The two W-DED processes explored were wire arc additive manufacturing (WAAM) and electron beam additive manufacturing (EBAM). High throughput inspection and tensile testing procedures were utilized to generate statistically relevant data sets related to each process and sample orientation. The 2 AM technologies produced material with remarkably different microstructures and mechanical properties. Importantly, results revealed key differences in strength and ductility for the two disparate processes which were found to be related to differences in the metallurgical properties.

• Research Organization: Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)
• Sponsoring Organization: USDOE National Nuclear Security Administration (NNSA)
• Grant/Contract Number: NA0003525
• OSTI ID: 2311519
• Report Number(s): SAND--2023-09188J
• Journal Information: Materials Characterization, Journal Name: Materials Characterization Vol. 205; ISSN 1044-5803
• Publisher: ElsevierCopyright Statement
• Country of Publication: United States
• Language: English