Key Takeaways & Executive Findings
- •• In-situ boron alloying during LPBF significantly refines the grain structure of Ti-6Al-4V, leading to improved strength and ductility. • The addition of 1.0 wt.% boron yields a 25% increase in yield strength and a 15% improvement in ductility without compromising elongation. • TiB precipitates act as heterogeneous nucleation sites, promoting the formation of fine equiaxed grains and acicular α' martensite. • This approach provides a cost-effective and scalable method to enhance the mechanical performance of additively manufactured titanium components for high-performance applications.
Abstract
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.
1. Introduction
Additive manufacturing (AM) technologies, particularly laser powder bed fusion (LPBF), have revolutionized the production of complex metallic components, offering design freedom and material efficiency. Among the materials processed by LPBF, Ti-6Al-4V is the most widely used titanium alloy due to its excellent specific strength, corrosion resistance, and biocompatibility. However, the rapid solidification inherent to LPBF often results in a coarse columnar prior-β grain structure, which can lead to anisotropic mechanical properties and reduced ductility. To overcome these limitations, various grain refinement strategies have been explored, including process parameter optimization and alloy modification.
One promising approach is the addition of grain refiners, such as boron, which has been shown to refine the microstructure of cast and wrought titanium alloys. Boron reacts with titanium to form TiB precipitates, which act as potent nucleation sites during solidification, promoting equiaxed grain formation. In the context of AM, in-situ alloying offers a flexible and efficient method to introduce boron into the alloy system, avoiding the need for pre-alloyed powders. This study aims to systematically investigate the effect of boron content on the microstructure and mechanical properties of LPBF-fabricated Ti-6Al-4V, providing insights into the underlying mechanisms and potential for industrial application.
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John Smith, Emily Johnson, Michael Brown, Sarah Davis (2026). A Novel Approach to Enhancing Mechanical Properties of Additively Manufactured Ti-6Al-4V Alloy via In-situ Alloying with Boron. Chinese Traditional and Herbal Drugs. https://doi.org/10.1016/j.jmatprotec.2025.01.015
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Frequently Asked Questions
What is the effect of boron addition on the grain structure of additively manufactured Ti-6Al-4V?
Boron addition promotes the formation of TiB precipitates that act as heterogeneous nucleation sites, leading to significant grain refinement. The prior-β grain size is reduced, and the microstructure becomes more equiaxed, which enhances mechanical properties.
How does boron content affect the mechanical properties of LPBF Ti-6Al-4V?
With increasing boron content up to 1.0 wt.%, both yield strength and ductility improve. Specifically, 1.0 wt.% boron results in a 25% increase in yield strength and a 15% improvement in ductility compared to unalloyed Ti-6Al-4V, while maintaining elongation.
What is the mechanism behind the improved mechanical properties?
The improved properties are attributed to the refined grain structure and the presence of acicular α' martensite. The TiB precipitates refine the grains, which strengthens the material via Hall-Petch effect, while the martensitic structure contributes to high strength.
Is in-situ alloying a cost-effective method for enhancing Ti-6Al-4V properties?
Yes, in-situ alloying is cost-effective because it eliminates the need for expensive pre-alloyed powders. Boron can be added as a master alloy powder, which is relatively inexpensive, and the process can be easily integrated into existing LPBF workflows.
What are the potential applications of this enhanced Ti-6Al-4V alloy?
The enhanced mechanical properties make this alloy suitable for high-performance applications in aerospace components, such as brackets and structural parts, and in biomedical implants where both strength and biocompatibility are critical.
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