TiAl Alloy Fabricated Using Election Beam Selective Melting: Process, Microstructure, and Tensile Performance

TiAl alloy is one of the most attractive candidates for a new generation of high-temperature structural materials and has broad application prospects in the aerospace field. As a typical intermetallic material, TiAl is inevitably difficult to process using conventional methods. Election beam selective melting (EBSM) is an effective method of addictive manufacturing to prepare TiAl alloy with a complex structure. However, the microstructure of TiAl alloy formed using EBSM often contains defects such as pores, which seriously reduces the mechanical properties of the material. In this work, the effects of EBSM and post-processing procedures on the microstructure and mechanical properties of Ti-48Al-2Cr-2Nb alloy were studied. The results show that the microstructure of Ti-48Al-2Cr-2Nb alloy formed using the EBSM process was dense and composed of equiaxed γ-phase and double-phase regions. A large number of dislocations that formed due to thermal stress were clearly observed inside the Ti-48Al-2Cr-2Nb alloy. When the EBSM process parameters were 13.5 mA, 4.0 m/s, and 40.50 J/mm3, as the current intensity increased, the Al content decreased, the content of α2 phase increased, and the microstructure of the material was coarse. The results of the tensile test fracture morphology indicate that the Ti-48Al-2Cr-2Nb alloy exhibited brittle fracture during tensile deformation, lacking the typical yield deformation of metal materials. As the energy density of the EBSM process increased, the mechanical properties of the Ti-48Al-2Cr-2Nb alloy first increased and then decreased. The samples prepared with an energy density of 34.50~40.50 J/mm3 had excellent mechanical properties, of which the maximum tensile strength and maximum elongation reached 643 MPa and 2.09%, respectively. The phase composition of the Ti-48Al-2Cr-2Nb alloy after hot isostatic pressing (HIP) treatment remained unchanged from the EBSM samples, but there was a slight difference in content. There was an increase in the amount of γ phase and a decrease in B2 phase, accompanied by the generation of a massive γ phase after HIP treatment. Moreover, the number of dislocations inside the material increased. The Ti-48Al-2Cr-2Nb alloy after HIP treatment exhibited obvious plastic deformation characteristics, with a tensile strength of 679 MPa and elongation of 2.5%. A heat treatment of 900 °C/5 h was performed on the Ti-48Al-2Cr-2Nb alloy after HIP. The dislocation density of the Ti-48Al-2Cr-2Nb alloy decreased, and the B2 phase transformed from massive to lamellar.