Achieving homogeneity in a high-Fe β-Ti alloy laser-printed from blended elemental powders

Blended Elemental powders are an emerging alternative to pre-alloyed powders in metal additive manufacturing due to the wider range of alloys producible with them and the cost savings from not developing novel feedstock. In this study, in situ alloying and concurrent microstructure evolution during SLM are investigated by performing SLM on a BE Ti-185 powder while tracking the surface temperatures via Infra-red imaging and phase transformation via synchrotron X-ray Diffraction. We then performed post-mortem electron microscopy (Backscatter Electron imaging, Energy Dispersive X-ray Spectroscopy and Electron Backscatter Diffraction) to further gain insight into microstructure development. We show that although exothermic mixing aids the melting process, laser melting results only in a mixture of alloyed and unmixed regions. Full alloying and thus a consistent microstructure is only achieved through further thermal cycling in the heat-affected zone.