The Influence of Process Parameters on the Density, Microstructure, and Mechanical Properties of TA15 Titanium Alloy Fabricated by Selective Laser Melting

With superior manufacturing freedom capability, Selective Laser Melting (SLM) technology is capable of fabricating high-strength Ti-6Al-2Zr-1Mo-1V (TA15) complex titanium alloy parts, thereby finding extensive applications in the aerospace sector. This paper primarily investigates the influence of process parameters on the relative density, microstructure, and mechanical properties of SLMed TA15 under conditions of similar laser linear energy density. The results indicate that the laser linear energy density significantly affects the single-track morphology of SLMed TA15; excessive energy density leads to keyhole defects, while insufficient energy density causes balling phenomena, resulting in discontinuous clad tracks. When the laser linear energy density is appropriate, the scanning spacing affects the forming density of the parts, with both excessively large and small spacings having adverse effects. With a fixed scanning spacing of 100 μm, high-density samples can be produced within a suitable range of linear energy density. However, when the laser linear energy density is comparable, a lower scanning speed leads to heat accumulation, causing in situ decomposition of the α’ martensite and the formation of coarser α + β phases, which reduces strength and hardness but improves plasticity. At a laser power of 90 W, a scanning speed of 400 mm/s, and a scanning spacing of 100 μm, the specimen exhibits a tensile strength of 1233 MPa and an elongation of 8.4%, achieving relatively excellent comprehensive properties.