Additive manufacturing of Ti-Al functionally graded material by laser based directed energy deposition

Abstract

Purpose

Ti-Al composite plates have been used in aerospace and other important fields for specific purposes in recent years. However, relatively few studies have concentrated on Ti-Al additive manufacturing because during additive manufacturing process the local fusion and mixing of Ti/Al are inevitable. These areas where Ti and Al are mixed locally, especially interface, could easily generate high residual stresses and cracks. This study aims to manufacture Ti-Al functionally graded material and investigate the interaction of interface.

Design/methodology/approach

In this study, Ti6Al4V/AlSi10Mg functionally graded materials were fabricated by laser based directed energy deposition (L-DED) and a strategy using V interlayer to relieve interfacial stress was investigated.

Findings

The area between the two materials was divided into transition zone (TZ) and remelting zone (RZ). The phase distribution, microstructure and micro-Vickers hardness of the TZ and RZ were investigated. Typical intermetallic compounds (IMCs) such as TiAl3, Ti3Al and Ti5Si3 were found in both composites. The addition of V interlayer promoted the homogenization of IMCs near interface and led to the formation of new phases like V5Si3 and Al3V.

Originality/value

The solidification process near the interface of Ti-Al functionally graded material and the possible generation of different phases were described. The result of this paper proved the feasibility of manufacturing Ti-Al functionally graded material by L-DED.

Citation

Chen, B., Wang, T., Xi, X., Tan, C. and Song, X. (2023), "Additive manufacturing of Ti-Al functionally graded material by laser based directed energy deposition", Rapid Prototyping Journal, Vol. 29 No. 3, pp. 558-568. https://doi.org/10.1108/RPJ-04-2022-0117