Microstructure of Interpass Rolled Wire + Arc Additive Manufacturing Ti-6Al-4V Components

Abstract Mechanical property anisotropy is one of the issues that are limiting the industrial adoption of additive manufacturing (AM) Ti-6Al-4V components. To improve the deposits’ microstructure, the effect of high-pressure interpass rolling was evaluated, and a flat and a profiled roller were compared. The microstructure was changed from large columnar prior $$\beta $$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:mi>β</mml:mi> </mml:math> grains that traversed the component to equiaxed grains that were between 56 and 139 μ m in size. The repetitive variation in Widmanstätten $$\alpha $$ <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML"> <mml:mi>α</mml:mi> </mml:math> lamellae size was retained; however, with rolling, the overall size was reduced. A “fundamental study” was used to gain insight into the microstructural changes that occurred due to the combination of deformation and deposition. High-pressure interpass rolling can overcome many of the shortcomings of AM, potentially aiding industrial implementation of the process.