Effect of Build Orientation of Electron Beam Melting on Microstructure and Mechanical Properties of Ti-6Al-4V

Build orientation influences thermal activity during the EBM process, thus affecting the resultant bulk material properties of the part being produced. This work focuses on EBM build orientation with respect to the X, Y and Z axes and its effect on microstructure and mechanical performance of Ti-6Al-4V parts. A series of EBM Ti-6Al-4V specimens were fabricated using an Arcam S12 setup in different build orientations: XY, ZX, ZY, XY 30° and XY 60° inclination to the start plate. Using conventionally wrought Ti-6Al-4V as a benchmark, EBM specimens were tensile and impact tested. Furthermore, microhardness measurements, optical and electron microscopy were used for characterization. Horizontally oriented EBM Ti-6Al-4V parts develop finer lamellar microstructures as a result of higher cooling rates, however exhibiting comparable strength and rather lower ductility and toughness when compared to vertically oriented parts. Solidification defects, resulting from inconsistencies in melting due to high cooling rates but also related to specimen geometry, have countered the influence of a finer microstructure. This study has also shown that EBM parts develop columnar prior-β grains which follow build direction. Benchmark wrought Ti-6Al-4V specimens show higher tensile properties while offering increased resistance to crack nucleation due to their homogeneous equiaxed microstructure.