On the viability of in-situ alloyed Ti-1Fe as a strong and ductile alternative to Ti-6Al-4V for laser-based powder bed fusion

Huang, Jeff; Issariyapat, Ammarueda; Kariya, Shota; Umeda, Junko; Kondoh, Katsuyoshi

doi:https://doi.org/10.1016/j.addma.2025.104788

On the viability of in-situ alloyed Ti-1Fe as a strong and ductile alternative to Ti-6Al-4V for laser-based powder bed fusion

Huang, Jeff; Issariyapat, Ammarueda; Kariya, Shota et al.

Additive Manufacturing, 2025, 105, 104788

Number of Access:164（2025-08-15 01:09 Counts）

Identifier to cite or link to this item: https://hdl.handle.net/11094/101396

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Title	On the viability of in-situ alloyed Ti-1Fe as a strong and ductile alternative to Ti-6Al-4V for laser-based powder bed fusion
Creator	CreatorName Huang, Jeff
	researchmap permalink ammarueda ammarueda Scopus Author ID 36833810800 36833810800 CreatorName Issariyapat, Ammarueda
	NRID 1000010912727 1000010912727 researchmap permalink kariya-s kariya-s Scopus Author ID 56865665900 56865665900 CreatorName Kariya, Shota
	NRID 1000050345162 1000050345162 ORCID 0000-0001-8678-9708 0000-0001-8678-9708 researchmap permalink umeda umeda Scopus Author ID 23478776500 23478776500 CreatorName Umeda, Junko
	NRID 1000050345138 1000050345138 researchmap permalink kondoh kondoh Scopus Author ID 9942942300 9942942300 CreatorName Kondoh, Katsuyoshi
Subject	Titanium
	Laser powder bed fusion
	In-situ alloying
	Microstructures
	Mechanical Properties
Description	Huang J., Issariyapat A., Kariya S., et al. On the viability of in-situ alloyed Ti-1Fe as a strong and ductile alternative to Ti-6Al-4V for laser-based powder bed fusion. Additive Manufacturing 105, 104788 (2025); https://doi.org/10.1016/j.addma.2025.104788.
Abstract	Developments in the additive manufacturing (AM) of titanium have historically centred around the market-leading Ti-6Al-4V alloy, with many studies aimed at adapting the seventy-year-old composition for newer AM processes such as laser-based powder bed fusion (PBF-LB/M). Amongst these studies, PBF-LB/M Ti-6Al-4V is usually shown to be remarkably strong (with gigapascal ultimate tensile strengths) and moderately ductile (if defect free), because of the ultra-fine martensitic α/α’ microstructures produced under the rapid cooling conditions of PBF-LB/M. However, despite these acceptable properties, the use of Ti-6Al-4V in AM fundamentally contradicts the original intention behind the design of this alloy composition, which relies on rare and expensive vanadium solutes to promote α+ β microstructures for good wrought-forming properties. In essence, neither the intended microstructures, nor the intended properties are relevant or compatible with near-net-shape AM processes. Therefore, it seems natural to question the strict adherence to conventional alloys in PBF-LB/M. In search of alternatives, the present study attempts to replicate the microstructures and properties of PBF-LB/M Ti-6Al-4V using the cheaper and leaner composition of Ti-1Fe prepared by in-situ alloying (i.e. from mixed elemental feedstocks). Both fine and coarse Fe particles were investigated to identify optimal feedstock characteristics and build parameters. In homogeneously mixed samples prepared from fine Fe particles at higher energy densities, similar microstructures to Ti-6Al-4V were successfully obtained, with corresponding tensile properties that exceed the performance requirements of ASTM F2924 (950 MPa yield strength, 12 % fracture strain). A theoretical analysis of strengthening mechanisms revealed significant contributions from grain refinement effects, dislocation hardening, and solid solution strengthening by oxygen and nitrogen interstitials. With these findings, we report for the first time the prerequisite conditions for obtaining strong and ductile tensile properties from as-built, in-situ alloyed Ti-1Fe as a potential low-cost alternative to Ti-6Al-4V for PBF-LB/M, and the problems that may occur with sub-optimal processing.
Publisher	Elsevier B.V.
Source Title	Additive Manufacturing
Volume (Issue)	105
Page	104788
Date of Issued	2025-04-18
Language	English
Handle URL	https://hdl.handle.net/11094/101396
eISSN	22148604
Relation.isIdenticalTo	DOI (Publisher Version) https://doi.org/10.1016/j.addma.2025.104788
Access Rights	open access
CopyRight	This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
oaire:version	Version of Record
Category	学術雑誌論文 Journal Article

Resource Type	journal article
Local Type	Journal Article
DCMI Type	Text
DCTERMS.bibliographicCitation	Additive Manufacturing. 2025, 105, p. 104788
DC.title	On the viability of in-situ alloyed Ti-1Fe as a strong and ductile alternative to Ti-6Al-4V for laser-based powder bed fusion
DC.creator	Huang, Jeff
	Issariyapat, Ammarueda
	Kariya, Shota
	Umeda, Junko
	Kondoh, Katsuyoshi
DC.publisher	Elsevier B.V.
DC.language' scheme='DCTERMS.RFC1766	English
DC.type' scheme='DCTERMS.DCMIType	Text
DCTERMS.issued' scheme='DCTERMS.W3CDTF	2025-04-18
DC.identifier	https://doi.org/10.1016/j.addma.2025.104788
DC.subject	Titanium
	Laser powder bed fusion
	In-situ alloying
	Microstructures
	Mechanical Properties
DC.description	Huang J., Issariyapat A., Kariya S., et al. On the viability of in-situ alloyed Ti-1Fe as a strong and ductile alternative to Ti-6Al-4V for laser-based powder bed fusion. Additive Manufacturing 105, 104788 (2025); https://doi.org/10.1016/j.addma.2025.104788.
DCTERMS.abstract	Developments in the additive manufacturing (AM) of titanium have historically centred around the market-leading Ti-6Al-4V alloy, with many studies aimed at adapting the seventy-year-old composition for newer AM processes such as laser-based powder bed fusion (PBF-LB/M). Amongst these studies, PBF-LB/M Ti-6Al-4V is usually shown to be remarkably strong (with gigapascal ultimate tensile strengths) and moderately ductile (if defect free), because of the ultra-fine martensitic α/α’ microstructures produced under the rapid cooling conditions of PBF-LB/M. However, despite these acceptable properties, the use of Ti-6Al-4V in AM fundamentally contradicts the original intention behind the design of this alloy composition, which relies on rare and expensive vanadium solutes to promote α+ β microstructures for good wrought-forming properties. In essence, neither the intended microstructures, nor the intended properties are relevant or compatible with near-net-shape AM processes. Therefore, it seems natural to question the strict adherence to conventional alloys in PBF-LB/M. In search of alternatives, the present study attempts to replicate the microstructures and properties of PBF-LB/M Ti-6Al-4V using the cheaper and leaner composition of Ti-1Fe prepared by in-situ alloying (i.e. from mixed elemental feedstocks). Both fine and coarse Fe particles were investigated to identify optimal feedstock characteristics and build parameters. In homogeneously mixed samples prepared from fine Fe particles at higher energy densities, similar microstructures to Ti-6Al-4V were successfully obtained, with corresponding tensile properties that exceed the performance requirements of ASTM F2924 (950 MPa yield strength, 12 % fracture strain). A theoretical analysis of strengthening mechanisms revealed significant contributions from grain refinement effects, dislocation hardening, and solid solution strengthening by oxygen and nitrogen interstitials. With these findings, we report for the first time the prerequisite conditions for obtaining strong and ductile tensile properties from as-built, in-situ alloyed Ti-1Fe as a potential low-cost alternative to Ti-6Al-4V for PBF-LB/M, and the problems that may occur with sub-optimal processing.
DC.rights	This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
DC.format	101396
citation_title	On the viability of in-situ alloyed Ti-1Fe as a strong and ductile alternative to Ti-6Al-4V for laser-based powder bed fusion
citation_author	Huang, Jeff
	Issariyapat, Ammarueda
	Kariya, Shota
	Umeda, Junko
	Kondoh, Katsuyoshi
citation_publisher	Elsevier B.V.
citation_language	English
citation_date	2025-04-18
citation_journal_title	Additive Manufacturing
citation_volume	105
citation_firstpage	104788
citation_doi	https://doi.org/10.1016/j.addma.2025.104788
citation_public_url	https://hdl.handle.net/11094/101396

On the viability of in-situ alloyed Ti-1Fe as a strong and ductile alternative to Ti-6Al-4V for laser-based powder bed fusion

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