Micromechanical characteristics of titanium alloy (Ti-6Al-4V) made by laser powder bed fusion using an in-situ SEM micropillar compression technique

While titanium alloy (Ti-6Al-4V) made by laser powder bed fusion (L–PBF) exhibits complex deformation behaviors, its important micromechanical properties in relation to loading directions are not fully understood. This research aims to investigate the micromechanical behaviors of printed L–PBF Ti-6Al-4V alloys under vertical (i.e., the loading direction perpendicular to printed layers) and horizontal (i.e., the loading direction parallel to printed layers) compressions using in-situ scanning electron microscopy (SEM) micropillar techniques. Ti-6Al-4V alloys were L-PBF-printed using a 45° rotate scanning strategy with vertical and horizontal build directions. The microstructures of the two alloys were analyzed using the SEM with energy-dispersive X-ray spectroscopy (EDS). The titanium alloy micropillars were produced using focused ion beam (FIB) milling in the SEM. In-situ SEM micropillar compressions were conducted using a flat diamond indenter. Vertical alloy had smaller cross-patterned finer α′ martensite than horizontal one. While both vertical and horizontal micropillars showed elastic-plastic behaviors, the former had significantly higher yield, fracture, and compression strength values, as well as resilience and toughness, than the latter, leading to the formation of favorable shear bands. Both micropillars exhibited ductile fractures but had distinct failure mechanisms. The ductile fracture in the vertical micropillars was due to strain hardening, large plastic deformation, and shear band formation, while the ductile fracture in the horizontal ones was attributed to compression-induced bending and plastic buckling. The micromechanical characteristics of L–PBF Ti-6Al-4V materials provides an important insight into the small-scale deformation and failure mechanisms of the alloys influenced by loading directions.