Influence of printing parameters on forming quality and indentation-derived mechanical properties of additively manufactured Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy

Purpose This study aims to overcome the limitations of conventional titanium manufacturing in producing complex aerospace components by establishing a multiscale-regulated manufacturing paradigm based on laser powder bed fusion (LPBF). It systematically examines the parameter–microstructure–performance relationship of the aviation-grade Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy to achieve near-net shaping through precise energy modulation. Design/methodology/approach LPBF processing was carried out within controlled parameter ranges: laser power 200–300 W, scanning speed 800–1,400 mm/s, layer thickness 30–60 µm, and hatch spacing 100–130 µm. The methodology involved analyzing deviations from volumetric energy density (VED) trends, introducing areal energy density (AED) as an optimization parameter, and applying real-time indentation for tensile strength prediction. Findings The performance of printed samples is governed by the coupled effects of laser parameters. Specimens with distinct layer thicknesses deviate from conventional VED trends, whereas areal energy density (AED) shows strong correlations with key material properties such as hardness, a′ phase dimensions, and tensile strength. In addition, real-time indentation achieved tensile strength prediction with less than 5% error. Originality/value This study establishes a parameter optimization benchmark for aerospace LPBF manufacturing. The AED-based approach reduces development cost and testing time, enabling rapid performance prediction via non-destructive indentation technology. By adopting AED as a key multi-objective optimization parameter and utilizing a real-time prediction model with industry-leading accuracy (<5% error), this work provides a multiscale control framework for manufacturing complex aerospace components.