Research Progress in Titanium Alloy Additive Manufacturing Under Different Energy Sources

Titanium alloys exhibit exceptional properties that enable their widespread application. Additive manufacturing (AM) technologies offer significant advantages for titanium alloy components, including rapid prototyping, high forming accuracy, and enhanced performance. Consequently, substantial research and industrial applications have emerged in the field of titanium alloy AM. Nevertheless, a systematic comparison and synthesis of related studies remains lacking. This paper reviews four distinct categories of titanium alloy AM processes classified by energy source (laser, electron beam, electric arc, and compressed air-assisted). Each category is analyzed in detail, with comparative assessments of microstructures, performance, and applications. Secondly, the paper comprehensively discusses current and potential applications of titanium alloy AM across aerospace, medical, and industrial sectors while identifying critical research gaps for future development. Finally, the development of novel titanium alloys for AM, titanium alloy AM assisted by acoustic or magnetic fields, and 4D printing of functional titanium alloys are discussed.