FAST-roll: Texture evolution and mechanical property assessment of low-cost Ti–6Al–4V plate from surplus powder

Low-cost titanium feedstock such as oversized additive manufacturing (AM) powders can be effectively consolidated into billets by the field-assisted sintering technology (FAST) process in the solid state with short processing times and reusable tooling. However, many engineering applications require material in the form of larger, flat plate or sheet product forms. By combining the FAST process with existing thermomechanical processing routes such as hot rolling, low-cost titanium plate or sheet can be produced in as little as two steps (FAST-roll). This study investigates the microstructural evolution, crystallographic texture and mechanical properties of FAST-roll plate derived from surplus AM powder. Comparisons are made with commercially available unidirectionally (UD) rolled plate material. Results show that the near-isotropic fine-grained microstructure of FAST-consolidated titanium lends itself to hot rolling. This results in the final plate product being less anisotropic and avoids the formation of macrozones, hence suggesting it is easier to form than conventional melt-wrought-derived material. This approach shows promise for developing low-cost, sustainable titanium plate and sheet for use in a range of engineering applications or further downstream processing.