Laser Powder Deposition Parametric Optimization and Property Development for Ti-6Al-4V Alloy

In this study, Ti6Al4V alloy was produced via laser powder deposition (LPD). To obtain Ti6Al4V alloy with maximum density, LPD parameters for preparing Ti6Al4V samples were optimized using the Taguchi method. Results were analyzed on the basis of the signal-to-noise (S/N) ratios and analyses of variance. A high energy density should be used to achieve higher levels of densification. The optimal combination of parameters for density was a scanning speed of 550 mm/min, laser power of 160 W, powder feeding rate of 0.99 g/min, and shield gas flow of 8 L/min. An almost fully dense Ti6Al4V sample was prepared using the optimized LPD process, and the relative density was greater than 99%. In addition, the microstructure and properties of Ti6Al4V samples prepared by optimized LPD process were investigated. The microstructure investigation revealed that the LPD-prepared Ti6Al4V sample was predominantly composed of fine acicular α phase and lath-type α phase. Tensile and microhardness tests indicated that the LPD sample had higher mechanical properties than the traditional cast Ti6Al4V alloy because of the acicular martensitic phase and smaller grain size.