Bridging Thermally Induced Sintering Results with Preheating During Powder Bed Fusion with Electron Beam for β-Ti21S

The metastable β-phase Ti21S titanium alloy, characterised by its low Young’s modulus, oxidation resistance, creep strength, and high biocompatibility, has potential applications in aeronautical and biomedical fields. Despite these advantages, its adoption in additive manufacturing (AM) processes, particularly powder bed fusion with electron beam (PBF-EB), remains limited. A critical aspect of PBF-EB is the sintering phenomenon during preheating, which influences powder behaviour, thermal dissipation, and part quality. Insufficient sintering leads to poor energy dissipation and charge accumulation, while excessive sintering compromises powder reusability. This study investigates the sintering conditions required to optimise the PBF-EB preheating step for Ti21S. Thermogravimetric (TG) apparatus was employed as a controlled thermal treatment system to conduct a preliminary screening of the influence of temperature on powder sintering over a range of 400 °C to 700 °C. Parallel experiments were conducted using a PBF-EB machine to evaluate sintering behaviour. Scanning electron microscopy (SEM) was used to analyse the degree of sintering, while powder reusability was assessed by comparing the morphology and flowability of virgin and reused powders. The results show that conventional thermal treatment and PBF-EB preheating produce different sintering responses, likely because of the localised and rapid energy deposition associated with electron-beam heating. Nevertheless, controlled thermal treatment may provide a preliminary screening method for identifying temperature ranges for subsequent PBF-EB optimisation.