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The purpose of this paper is the microstructural and mechanical characterization of a biomedical Ti‐6Al‐4V alloy produced by electron beam melting, and the study of the stability of the as‐built microstructure upon heat treatment.

Ti‐6Al‐4V alloy produced by electron beam melting has been mechanically characterized through tensile and fatigue testing. Its microstructure has been investigated by optical observation after etching and by X‐ray diffractometry analysis. The stability of the microstructure of the as‐built material has been deepened carrying out suitable heat treatments, after an analysis by dilatometry test.

The microstructure of a Ti‐6Al‐4V alloy produced by electron beam melting has a very fine and acicular morphology, because of the intrinsically high‐solidification rate of the process. This microstructure is very stable, and the traditional thermal treatments cannot modify it; the microstructure changes significantly only when an amount of strain is introduced in the material. However, the mechanical properties of the alloy produced by electron beam melting are good.

The paper provides evidence of the microstructural stability of the material produced by electron beam melting. Even if the microstructure of the as‐built material is not recommended by the specific ISO standard, the related mechanical properties are fully satisfactory. This is a significant indication from the point of view of the production of Ti‐6Al‐4V orthopaedic and dental prostheses by electron beam melting.

The aim of the paper is the study of the change in the mechanical properties (and in particular in ductility), with the microstructure, of a biomedical Ti‐6Al‐4V alloy produced by different variants of selective laser melting (SLM).

Ti‐6Al‐4V alloy produced by different variants of SLM has been mechanically characterized through tensile testing. Its microstructure has been investigated by optical observation after etching and by X‐ray diffraction analysis.

SLM applied to Ti‐6Al‐4V alloy produces a material with a martensitic microstructure. Some microcracks, due the effect of incomplete homologous wetting and residual stresses produced by the large solidification undercooling of the melt pool, are observable in the matrix. Owing to the microstructure, the tensile strength of the additive manufactured parts is higher than the strength of hot worked parts, whereas the ductility is lower. A pre‐heating of the powder bed is effective in assisting remelting and reducing residual stresses, but ductility does not increase significantly, since the microstructure remains martensitic. A post‐building heat treatment causes the transformation of the metastable martensite in a biphasic a‐b matrix, with a morphology that depends on the heat treatment. This results in an increase in ductility and a reduction in strength values.

The study evidenced how it is possible to obtain a fully dense material and make the martensite transform in Ti‐6Al‐4V alloy through the variation of the SLM process. The stabilization of the microstructure also results in an improvement of the ductility.

This paper aims to systematically investigate the effect of laser remelting on the surface morphology and mechanical properties of laser deposition manufactured thin-walled Ti-6Al-4V alloy.

Thin-walled Ti-6Al-4V samples were prepared by laser deposition manufacturing (LDM) method and subsequently surface-treated by laser remelting in a controlled environment. By experiments, the surface qualities and mechanical properties of LDM Ti-6Al-4V alloy before and after laser remelting were investigated.

After laser remelting, the surface roughness of LDM Ti-6Al-4V alloy decreases from 15.316 to 1.813 µm, hard and brittle martensite presents in the microstructure of the remelted layer, and the microhardness of the laser remelted layer increases by 11.39%. Compared with the machined LDM specimen, the strength of the specimen including the remelted layer improves by about 5%, while the elongation and fatigue life decrease by about 72.17% and 64.60%, respectively.

The results establish foundational data for the application of laser remelting to LDM thin-walled Ti-6Al-4V parts, and may provide an opportunity for laser remelting to process the nonfitting surfaces of LDM parts.