Characterization Of Ti-6AL-4V Direct-To-Metal Fabrication Of Aerospace Grade Applications

Direct Metal Fabrication (DMF) methods offer a highly flexible manufacturing method for aerospace grade metallic parts to be created from a Computer Aided Design (CAD) model. The ARCAM Electron Beam Melting (EBM) technology was down selected to evaluate Ti 6Al-4V and Ti 6Al-4V Extra Low Interstitials (ELI) for flightworthiness applications. Direct Metal Fabrication is very promising for the manufacture of aerospace components due to their complex geometries, long lead times for castings, forgings and complex computing of CNC machining. The applications for DMF range from: reverse engineering of legacy components, production for low to medium build quantities and rapid manufacture of prototype applications. The mechanical and metallurgical properties of three heat treatments were evaluated: Annealed (as-fabricated), Hot Isostatic Press (HIP) only, Hot Isostatic Press plus Beta Solution Treat and Overage (HIP+BSTOA). This paper presents the mechanical and metallurgical test data of Electron Beam Melted Ti 6Al-4V relative to other manufacturing methods and compares heat treatment process effects.