Investigating Complex Geometrical Features in LPBF-Produced Parts: A Material-Based Comparison Between Different Titanium Alloys

Abstract The Ti–6Al–4V (Ti64) alloy is a well-established material to be processed via laser powder bed fusion (LPBF). Recently, other α + β titanium alloys are receiving attention, such as Ti–6Al–2Sn–4Zr–6Mo (Ti6246). Their typical industrial fields of application (aerospace, automotive), often require critical design choices, such as low wall thicknesses and hollow channels. Thus, a comparative analysis between these two competitor alloys in terms of processability was conducted in this work. To do so, specific sample designs were developed. The specimens were analyzed in terms of geometrical compliance with the initial design, porosity, and microstructure. A correlation between the width of the specimens and their porosity, microstructure and hardness was found. Overall, both the alloys proved to be well processable, even for very low wall thickness (300 μm) and channel diameter (1 mm) values. Nevertheless, the Ti6246 alloy seemed to behave better in specific scenarios. For instance, some Ti64 specimens provided delamination. The hollow channels proved to be challenging for both materials, mainly due to the high amount of residual powder particles adhered to the upper part of the holes. This works aims at giving a materials perspective on process-related issues, considering the LPBF-induced defectology and microstructural variations in these Ti alloys. Graphical Abstract