Computational Evaluation of Temperature-Dependent Microstructural Transformations of Ti6Al4V for Laser Powder Bed Fusion Process

In-situ decomposition in the laser powder bed fusion process enables the α’ martensite to transform into lamellar (α + β) microstructures to achieve superior mechanical properties, yet special conditions are required for the formation of decomposition, and these conditions are difficult to predict. In this context, an efficient model has been developed to evaluate the ever-changing thermal behavior of the multi-tracks and multi-layer laser scanning process. The model includes empirical approaches to determine conductivity enhancement factor in the z-direction (λ_z) and absorptivity for Ti6Al4V. Furthermore, the temperature-dependent microstructural transformations in relation to process parameters and the required stages of martensite decomposition are explained. The model produced consistent results for parameters selected from the literature that allow martensite decomposition. In addition, parameters were estimated for a powder layer thickness of 30 μm and a laser with a beam diameter of 85 μm, where martensite decomposition would be difficult. A cuboid sample was designed to be manufactured on a commercial machine. Despite the limitations in the machine, the martensite decomposition was able to be initiated in the center of the sample by enlarging its dimensions. This shows that lamellar structures with a layer thickness of 30 micrometers can be produced under favorable conditions.