Experimental and Crystal Plasticity Finite Element Investigations of Plastic Anisotropy in Additively Manufactured Ti6Al4V Alloy

Additive manufacturing, particularly the laser powder bed fusion (LPBF) technique, has ushered in a new era of intricate metallic component fabrication, leveraging the exceptional performance of the Ti6Al4V alloy. However, the intricate mechanical behavior of additively manufactured Ti6Al4V, particularly its anisotropic attributes stemming from non-equilibrium microstructures, presents a formidable challenge. In this study, we embark on a comprehensive exploration of the anisotropic mechanical properties exhibited by LPBFed Ti6Al4V alloy. The interplay between microstructure and tensile response is unraveled by integrating experimental investigations with crystal plasticity finite element (CPFE) simulations. The acquired empirical data with CPFE model predictions are harmonized through systematic tensile tests along distinct processing orientations. The results unveil the genesis of plastic anisotropy within the LPBFed Ti6Al4V alloy, ascribed to the emergence of columnar grains meticulously aligned along the building direction, despite the intricate material microstructure inherent to additive manufacturing. These findings collectively furnish a holistic comprehension of the intricate nexus between material attributes and the mechanical manifestations intrinsic to metal components realized through additive manufacturing modalities.