Synchrotron X-ray imaging of directed energy deposition additive manufacturing of titanium alloy Ti-6242

Directed Energy Deposition Additive Manufacturing (DED-AM) is transformative for the production of larger, geometrically complex metallic components. However, the mechanical properties of titanium alloy DED-AM components do not always reach their full potential due to microstructural features including porosity and regions of lack of fusion. Using in situ and operando synchrotron X-ray imaging we gain insights into key lasermatter interaction and microstructural feature formation mechanisms during DED-AM of Ti-6242. Analysis of the process conditions reveals that laser power is dominant for build efficiency while higher traverse speed can effectively reduce lack of fusion regions. We also elucidate the mechanisms underlying several physical phenomena occurring during the deposition of titanium alloys, including the formation of a saddle-shaped melt pool and pore pushing. The findings of this work clarify the transient kinetics behind the DED-AM of titanium alloys and can be used as a guide for optimising industrial additive manufacturing processes.

Automated summary

The study investigates the process conditions of manufacturing titanium alloy components using directed energy deposition additive manufacturing, revealing that laser power dominates build efficiency and higher traverse speed can effectively reduce lack of fusion regions. Additionally, mechanisms behind physical phenomena such as the formation of a saddle-shaped melt pool and pore pushing are elucidated.