EBW and LBW of Additive Manufactured Ti6Al4V Products

This study investigated the weld joint properties of additive manufactured (AM) titanium parts.The welding experiments were performed using 4-kW fiber laser beam welding (LBW) and 30-kW, 80-kV electron beam welding (EBW).Wrought Ti6Al4V welded parts were compared to AM welded parts.In addition, the combination of welding AM parts to wrought (Ti6Al4V) parts was examined.The welds were analyzed and compared in terms of weld bead profile, tensile strength, microhardness, macro examination, and nondestructive testing.The results revealed certain differences between the welds of AM parts and the welds of wrought parts.Significant differences were found in the weld fusion zone (FZ) and in the material's thermal conductivity below the  transus.The FZ boundary on the AM side of the joint was wider and had a straight shape versus the neck-shaped FZ boundary on the wrought material side.A thermal finite element model was used to simulate LBW.The simulation supported the experimental observations.The results indicate it is possible to achieve good-quality welds of AM to AM, and of AM to wrought material, for aerospace applications using both EBW and LBW.