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Published Research PapersFiltered: Year 2025 • Vol. 325

Showing 5 of 30 peer-reviewed papers with full Graphical Abstracts.

Original ResearchVol. 325, Issue 1 • pp. 118-129DOI: 10.1016/j.jmatprotec.2025.01.001

A Novel Approach to Enhancing Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via Friction Stir Processing

Authors: John Smith, Emily Johnson, Michael Brown, Sarah Davis

Additive manufacturing (AM) of Ti-6Al-4V alloy offers significant design freedom but often results in microstructural inhomogeneities and reduced mechanical properties compared to wrought counterparts. This study introduces a novel post-processing technique combining friction stir processing (FSP) with a subsequent heat treatment to refine the microstructure and enhance tensile and fatigue properties. The results demonstrate a 25% increase in yield strength and a 40% improvement in fatigue life, attributed to the elimination of porosity and the formation of a fine bimodal microstructure. The proposed method provides a scalable solution for improving the reliability of AM components in aerospace and biomedical applications.

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A Novel Approach to Enhancing Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via Friction Stir Processing

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Original ResearchVol. 325, Issue 1 • pp. 118-132DOI: 10.1016/j.jmatprotec.2025.01.015

A Novel Approach to Enhancing the Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via In-situ Alloying with Boron

Authors: John Smith, Emily Johnson, Michael Brown, Sarah Davis

This study presents a novel approach to enhance the mechanical properties of additively manufactured Ti-6Al-4V alloy through in-situ alloying with boron. Boron was introduced into the titanium alloy matrix during the laser powder bed fusion process, resulting in a refined microstructure and improved tensile strength and ductility. The effects of boron content on the microstructure, phase composition, and mechanical properties were systematically investigated. The results demonstrate that the addition of 0.5 wt% boron leads to a significant grain refinement, with a reduction in prior β grain size from 200 μm to 50 μm. Consequently, the yield strength increased by 15% and the elongation improved by 20% compared to the unmodified alloy. The underlying strengthening mechanisms, including grain boundary strengthening and solid solution strengthening, are discussed. This work provides a promising pathway for tailoring the mechanical performance of additively manufactured titanium alloys for high-performance applications.

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A Novel Approach to Enhancing the Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via In-situ Alloying with Boron

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Original ResearchVol. 325, Issue 1 • pp. 118-132DOI: 10.1016/j.jmatprotec.2025.01.001

A Novel Approach to Enhancing Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via In-situ Ultrasonic Vibration

Authors: John A. Smith, Emily R. Johnson, Michael T. Brown

Additive manufacturing (AM) of Ti-6Al-4V alloy often results in undesirable microstructures and mechanical properties due to rapid solidification and thermal cycling. This study introduces a novel in-situ ultrasonic vibration-assisted laser powder bed fusion (LPBF) technique to refine the microstructure and enhance mechanical properties. The effects of ultrasonic vibration amplitude on porosity, grain morphology, and tensile properties were systematically investigated. Results show that applying ultrasonic vibration during LPBF significantly reduces porosity, promotes the formation of fine equiaxed grains, and improves both yield strength and ductility. The optimal vibration amplitude of 30 μm resulted in a 15% increase in yield strength and a 20% improvement in elongation compared to conventional LPBF. Microstructural analysis revealed that ultrasonic vibration induces cavitation and acoustic streaming, which enhance melt pool convection and promote heterogeneous nucleation. This work provides a promising pathway for producing high-performance Ti-6Al-4V components via AM.

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A Novel Approach to Enhancing Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via In-situ Ultrasonic Vibration

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Original ResearchVol. 325, Issue 2 • pp. 118-132DOI: 10.1016/j.jmatprotec.2025.01.015

A Novel Approach to Enhancing Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via In-situ Alloying with Boron

Authors: John Smith, Emily Johnson, Michael Brown, Sarah Davis

This study investigates the effect of in-situ boron alloying on the microstructure and mechanical properties of Ti-6Al-4V components fabricated by laser powder bed fusion (LPBF). Boron additions of 0.5, 1.0, and 1.5 wt.% were introduced via a master alloy powder. Microstructural characterization using SEM and EBSD revealed significant grain refinement with increasing boron content, attributed to the formation of TiB precipitates that act as heterogeneous nucleation sites. Tensile testing showed that the addition of 1.0 wt.% boron resulted in a 25% increase in yield strength and a 15% improvement in ductility compared to the unalloyed Ti-6Al-4V, while maintaining comparable elongation. The enhanced mechanical properties are correlated with the refined prior-β grain structure and the presence of acicular α' martensite. This work demonstrates a promising pathway for tailoring the mechanical performance of additively manufactured titanium alloys through in-situ alloying, offering potential for aerospace and biomedical applications.

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A Novel Approach to Enhancing Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via In-situ Alloying with Boron

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Original ResearchVol. 325, Issue 2 • pp. 118045DOI: 10.1016/j.jmatprotec.2025.01.015

Optimization of Process Parameters for Laser Powder Bed Fusion of AlSi10Mg Alloy: A Multi-Objective Approach

Authors: John Smith, Emily Johnson, Michael Brown, Sarah Davis

Laser powder bed fusion (LPBF) is a prominent additive manufacturing technique for producing complex metallic components. However, the quality of LPBF parts is highly dependent on process parameters, which often require extensive experimental tuning. This study presents a systematic multi-objective optimization of LPBF process parameters for AlSi10Mg alloy to simultaneously improve density, surface roughness, and mechanical properties. A response surface methodology (RSM) combined with a desirability function approach was employed to optimize laser power, scan speed, and hatch spacing. The results indicate that an optimal parameter set (laser power: 350 W, scan speed: 1200 mm/s, hatch spacing: 0.12 mm) yields a relative density of 99.8%, surface roughness (Ra) of 6.2 μm, and ultimate tensile strength of 420 MPa. Microstructural analysis revealed a fine cellular structure with minimal porosity. The optimized parameters were validated experimentally, showing excellent agreement with predicted values. This work provides a robust framework for efficient parameter optimization in LPBF, reducing trial-and-error efforts and enhancing part quality for industrial applications.

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Optimization of Process Parameters for Laser Powder Bed Fusion of AlSi10Mg Alloy: A Multi-Objective Approach

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