Validation of Profilometry‐Based Indentation Plastometry (PIP) Testing for Rapid Qualification of Electron Beam‐Powder Bed Fusion (EB‐PBF) With Ti–6Al–4V Builds

Alloy additive manufacturing demonstrates significant promise for use in structural and functional applications involving extreme temperatures and pressures. Advances in electron beam‐based additive manufacturing are especially interesting for near‐net‐shape refractory alloy‐based components. However, it is critical to address the ability to consistently manufacture components with desired thermomechanical properties. This article employs profilometry‐based indentation plastometry (PIP) for rapid evaluation of thermomechanical properties of Ti–6Al–4V builds manufactured by a new electron beam‐powder bed fusion (EB‐PBF) instrument. PIP results are validated by a set of multiscale characterization techniques: nanoindentation, Vickers microhardness, and conventional tensile testing. Microstructure is characterized to understand the structure–process–mechanical property relationships. Average yield strength from room‐temperature PIP (909–934 MPa) closely matches average yield from tensile testing (912 MPa). High‐temperature (600°C) PIP showed a 45% yield strength reduction. Creep effects are investigated at room and elevated temperature with a range of tip velocities and strain rates, and strain sensitivity values were calculated: m RT = 0.018, m 600°C = 0.16. At room temperature, PIP is capable of predicting mechanical properties up to 4x faster than conventional mechanical testing methods. Results show consistent properties across manufactured component with some deviation when probing properties along the EB‐PBF melt layer axis.