Optimization of Microstructure and Strength–Ductility Synergy in Selective Laser-Melted Ti6Al4V Alloy via Chessboard Scanning Strategy

To optimize the microstructure and mechanical properties of Ti6Al4V alloys fabricated via Selective Laser Melting (SLM), this study proposes an optimization approach based on the chessboard scanning strategy. A systematic comparison of three scanning strategies—alternating, stripe, and chessboard scanning—was conducted to examine their effects on thermal input distribution, grain refinement, phase composition, and mechanical performance. Characterization results from Scanning Electron Microscopy (SEM), Electron Backscatter Diffraction (EBSD), and Transmission Electron Microscopy (TEM) revealed that the chessboard scanning strategy effectively refines the grain size to 88.64 ± 10.79 μm and increases the strengthening phase α′ content to 53.3%. Mechanical testing showed a tensile strength of 1179 ± 17 MPa (11.02% higher than stripe scanning) and elongation of 7.9 ± 0.4%. This strategy promotes random grain orientation by altering the scanning path, disrupting directional solidification, and suppressing texture formation. Microstructural mechanism analysis suggests that dislocation strengthening, increased α′ content, and grain refinement synergistically enhance both strength and ductility. These findings provide theoretical support for optimizing SLM parameters and the design of Ti6Al4V alloys’ microstructure and mechanical properties.