On the effect of energy input on microstructure evolution and mechanical properties of laser beam powder bed fusion processed Ti-27Nb-6Ta biomedical alloy

Additive manufacturing of pre-alloyed Ti-27Nb-6Ta powder by laser beam powder bed fusion (PBF-LB/M) employing a wide range of processing parameters is reported. An in-depth microstructure analysis along the whole process chain from powder feedstock material to additively manufactured bulk structures was conducted employing scanning electron microscopy (SEM) as well as X-ray and high-energy synchrotron diffraction. It is shown that near-fully dense parts (≥ 99.96%) with β+α’’ dual-phase microstructure and very homogenous element distribution are obtained in a large process window. In particular, a considerable influence of the energy input during PBF-LB/M on the solidification microstructure, i.e. phase composition and texture, is found. With increasing energy per unit area (E A ) values both an increase in the volume fraction of the bcc β-phase and more pronounced texture components are seen. Furthermore, the mechanical behavior was evaluated under monotonic tensile loading. The PBF-LB/M processed Ti-27Nb-6Ta structures feature good mechanical properties with ultimate tensile strength (UTS) and strain to failure values of up to 768 MPa and 33.8 %, respectively. Due to the strong impact of the energy input during additive manufacturing on the microstructure evolution, however, a significant inverse strength-ductility behavior is observed. While UTS clearly decreases with increasing E A values, strain to failure increases at the same time. The underlying relationships between processing (energy input), microstructure and mechanical properties are explored and rationalized. • Additive manufacturing (AM) of pre-alloyed Ti-Nb-Ta powder by laser beam powder bed fusion (PBF-LB/M). • Chemically homogenous AM structures with near full density in a wide range of processing parameters. • Energy input during processing allows to tailor microstructure, phase constitution and mechanical properties of as-built parts. • The findings presented establish pathways for direct microstructure design in envisaged implant applications.