Microstructure, Variants, and Mechanical Properties of the Thin‐Walled Components of Ti–6.5Al–2Zr–1Mo–1V Titanium Alloy Manufactured by Electron Beam Melting

The thin‐walled components of Ti–6.5Al–2Zr–1Mo–1V titanium alloy, with a wall thickness of 2.5 mm, are manufactured using electron beam melting. The effect of energy density on microstructure and mechanical properties is investigated. The results show that needle‐like α′ phases are gradually transformed into the clustered martensite with the same orientation, forming a networked structure of interwoven clustered and needle‐like martensite. The increasing area fraction of clustered martensite expands the range and trend of variant selection. When energy density is 42 J mm −3 , the maximum surface density (99.94%) of the alloy is achieved, with a tensile strength of 1100 MPa and elongation of 13.2%; and its average microhardness value is 390.2HV 0.1 . This strength–ductility balance is optimal, corresponding to a network structure of clustered and needle‐like martensite. Clustered martensite increases the effective martensite size, enhancing the dislocation slip length during deformation. Therefore, the strength of alloy is reduced but its plasticity is improved.