X-ray micro-computed tomography of porosities in large-volume 3D-printed Ti–6Al–4V components using laser powder-bed fusion and their tensile properties

Characterization of defects in large 3D printed metals is critical but challenging. This study reports on the X-ray micro-computed tomography (micro-CT) examination of porosities in large-volume 3D-printed and heat-treated titanium (Ti–6Al–4V) alloys, together with their tensile properties and failure mechanisms. Titanium alloy powders were analyzed using scanning electron microscopy (SEM). Laser powder bed fusion (L-PBF) was used to print titanium alloy specimens vertically and horizontally, followed by stress-relieved heat treatment. Micro-CT imaging was performed on printed specimens of 10 × 20 mm³ (diameter × length) to determine their porosities, pore locations and size distributions using an industrial micro-CT system and relevant imaging software. Tensile testing of the processed specimens was conducted to determine their mechanical properties. Optical microscopy and SEM were used to examine the tension-induced failure mechanisms. The results show that porosities, pore sizes and locations were influenced by the build direction, resulting in different mechanical properties. Horizontal printing achieved higher tensile modulus, strength, ductility, resilience and toughness than vertical printing. Heat treatment did not change porosities in horizontally built specimens, but slightly reduced porosities for vertically built ones by 10%. This led to most mechanical properties nearly unchanged for the horizontally printed specimens but remarkably increased yield and tensile strength, and resilience, for the vertically printed ones. All tension-induced fractured surfaces contained pores, possible indicators of failure origins, which should be diminished in advanced processes for higher mechanical reliability.