Development of a novel TiAl-Ti6Al4V alloy via laser powder bed fusion

• Develop 50%TiAl-50%Ti64 alloy via L-PBF, addressing crack sensitivity. • Metastable microstructure: β at room temp, β + α 2 after heat treatment. • EBSD analysis: 99% columnar β phase in as-built, fine grains with 41.3% β post-heat. • Moderate hardness and deformation, bridging TiAl and Ti64 alloy properties. A novel 50 % TiAl–50 % Ti6Al4V (wt%) alloy was fabricated using laser powder bed fusion (L-PBF). Rapid cooling during L-PBF stabilized the high-temperature β phase in this innovative blend. This β stabilization effectively prevented the formation of cracks, resulting in a favorable metastable microstructure suitable for room and high-temperature applications. Detailed analysis using EBSD revealed a 99 % presence of β phase at room temperature, which transitions to α 2 + β at elevated temperatures, as 600 °C, in the current study. Mechanical tests revealed moderate hardness (460 HV) and ductility, effectively bridging the properties of TiAl and Ti6Al4V for structural and energy applications.