Manufacturing and characterization of in-situ alloyed Ti6Al4V(ELI)-3 at.% Cu by laser powder bed fusion

Biofunctionalization of Ti6Al4V alloy with metallic agents like Ag or Cu is a promising approach to add antibacterial properties and thus to reduce the risk of implant failure. This research investigates the in-situ alloying of Ti6Al4V(ELI) with 3 at.% Cu powders using Laser Powder Bed Fusion (L-PBF). The morphology and geometrical characteristics of the single tracks and layers were studied. Laser powers of 170 W and 340 W, and scanning speeds ranging from 0.4 to 1.4 m/s and 0.8–2.8 m/s were implemented. Single track results showed balling effect and humping at high scanning speeds, 1.4 m/s and 1.6 m/s, for each laser powder respectively. Conversely, keyhole formation occurred at lower scanning speeds of 0.4–0.6 m/s for 170 W laser power, and below and 0.8 m/s for 340 W laser power. For both laser powers, single layers resulted in smoother surfaces at lower scanning speeds. These results were used for the development of optimal process parameters for 3D cubes with 99.9 % density. Optimal process parameters were found for 170 W and 340 W laser powders at 0.7−0.9 and 1.0–1.2 m/s scanning speeds, respectively. In-situ alloying by L-PBF was challenging and a homogeneous distribution of Cu within the alloy was hard to achieve. The increase in laser power from 170 to 340 W resulted in small increase in homogenization. Microstructural analyses after stress-relieving treatment showed the presence of α' and β phases, as well as CuTi2 intermetallic precipitates. The finer microstructure together with CuTi2 intermetallic precipitates resulted in an increase in hardness. This study demonstrates the potential for printing in-situ alloyed Ti6Al4V(ELI)- 3 at.% Cu for biomedical applications. However, further studies are required to determine the effectiveness of antibacterial properties.