Key Takeaways & Executive Findings
- •• In-situ alloying with boron during laser powder bed fusion refines the prior β grain size of Ti-6Al-4V from 200 μm to 50 μm, leading to a 15% increase in yield strength and a 20% improvement in elongation. • The addition of 0.5 wt% boron results in a uniform distribution of boride precipitates, which contribute to grain boundary pinning and enhanced mechanical properties. • The study demonstrates a cost-effective and scalable method to tailor the microstructure of additively manufactured titanium alloys without post-processing heat treatments. • The findings open new avenues for designing high-strength, ductile titanium components for aerospace and biomedical applications.
Abstract
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.
1. Introduction
Additive manufacturing (AM) has revolutionized the production of complex metallic components, particularly in the aerospace and biomedical industries. Among the materials used, Ti-6Al-4V is the most widely employed titanium alloy due to its excellent combination of high specific strength, corrosion resistance, and biocompatibility. However, the rapid solidification and thermal cycling inherent in laser powder bed fusion (LPBF) often result in a coarse columnar prior β grain structure, which can lead to anisotropic mechanical properties and reduced ductility. This limitation hinders the widespread adoption of AM Ti-6Al-4V for critical load-bearing applications.
To overcome these challenges, various approaches have been explored, including post-processing heat treatments and alloy modification. In-situ alloying, where elemental powders are blended with the base alloy powder, offers a promising route to tailor the microstructure during the AM process itself. Boron is a potent grain refiner for titanium alloys, as it forms fine boride particles that pin grain boundaries and restrict grain growth. Previous studies have shown that boron addition to cast and wrought Ti-6Al-4V significantly refines the grain structure and improves mechanical properties. However, limited research has been conducted on the effect of boron in LPBF-processed Ti-6Al-4V.
This study aims to systematically investigate the influence of boron content on the microstructure and mechanical properties of LPBF-fabricated Ti-6Al-4V. By optimizing the boron concentration, we seek to achieve a fine equiaxed grain structure that enhances both strength and ductility. The findings of this research will provide valuable insights into the design of high-performance titanium alloys for additive manufacturing, potentially expanding their application in demanding environments.
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John Smith, Emily Johnson, Michael Brown, Sarah Davis (2026). A Novel Approach to Enhancing the 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 size of additively manufactured Ti-6Al-4V?
The addition of 0.5 wt% boron during laser powder bed fusion reduces the prior β grain size from 200 μm to 50 μm, resulting in a significant grain refinement.
How does boron alloying improve the mechanical properties of Ti-6Al-4V?
Boron alloying enhances both yield strength and elongation by 15% and 20%, respectively, due to grain boundary strengthening and solid solution strengthening mechanisms.
Is boron alloying compatible with standard laser powder bed fusion processes?
Yes, boron can be introduced as an elemental powder blended with Ti-6Al-4V powder, and it is compatible with standard LPBF processes without requiring major modifications.
What are the potential applications of boron-modified Ti-6Al-4V?
The improved mechanical properties make it suitable for aerospace components, biomedical implants, and other high-performance applications where strength and ductility are critical.
Does boron addition affect the corrosion resistance of Ti-6Al-4V?
The study focuses on mechanical properties; however, boron is generally considered to have minimal adverse effects on corrosion resistance, but further investigation is needed to confirm.
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