Build Strategy Investigation of Ti-6Al-4V Produced via a Hybrid Manufacturing Process


Hybrid manufacturing (HM), which integrates additive and subtractive manufacturing in one system, has become a popular choice for near-net-shape fabrication of complex parts. Although HM systems have been investigated for decades with major efforts on hardware and motion control system development, less work has been done in the exploration of relationships between microstructure evolution and the HM processing parameters. Here, Ti-6Al-4V thin-wall structures are fabricated according to a design of experiments matrix that includes four main HM processing parameters: layer height, powder feed rate, input energy density, and preheat condition. Optical microscopy is used to characterize the microstructure and relate it to the final part mechanical properties using Vickers hardness test and tensile test. Finite element analysis is applied to predict transient temperature history in the HM process and to help understand the microstructure type formation.


Materials Science and Engineering

Second Department

Mechanical and Aerospace Engineering

Research Center/Lab(s)

Intelligent Systems Center


This project was supported by The Boeing Company through the Center for Aerospace Manufacturing Technologies (CAMT), National Science Foundation Grants #CMMI-1547042 and CMMI-1625736, and the Intelligent Systems Center (ISC) at Missouri S&T.

Keywords and Phrases

Aluminum alloys; Design of experiments; Manufacture; Microstructure; Motion control; Tensile testing; Ternary alloys; Vanadium alloys; Vickers hardness; Vickers hardness testing, Complex parts; Manufacturing process; Micro-structure evolutions; Near net shape; Powder feed rate; Processing parameters; Thin-wall structures; Transient temperature history, Titanium alloys

International Standard Serial Number (ISSN)

1047-4838; 1543-1851

Document Type

Article - Journal

Document Version


File Type





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Publication Date

01 Sep 2018