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Titanium aluminides processing by additive manufacturing – a review

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Abstract

Manufacturing titanium aluminides (TiAls) parts are challenging due to their low ductility and fracture toughness. However, processing these materials is of significant interest for applications in high-temperature environments such as the aerospace and automotive industries. Traditional production methods such as casting and forging have been prominent in TiAl manufacturing. Currently, direct energy deposition (DED), electron beam additive manufacturing (EBAM), and laser powder bed fusion (L-PBF) additive manufacturing processes are being considered promising technologies for manufacturing TiAl parts. Recent results suggest the potential for these AM methods to be used for the industrial processing of TiAls. This article reviews the different processing methods for TiAls, highlighting the advantages and progress in using additive manufacturing (AM) technologies. Process characteristics, processing challenges and their causes, and potential mitigation strategies are discussed for each AM method considered. The process-structure–property (PSP) relationships are reviewed, highlighting the optimum process parameters and related mechanical properties. In addition, L-PBF is emphasized as a prospective solution for manufacturing different TiAl alloys. Prospects and recommendations for future studies are also suggested.

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Abbreviations

AM:

Additive manufacturing

BDTT:

Brittle to ductile transition temperature

CAD:

Computer-aided design

DED:

Direct energy deposition

E:

Energy density

EBAM:

Electron beam-powder bed fusion

EBSD:

Electron back scattered diffraction

FGM:

Functionally graded material

GO:

Graphene oxide

h:

Hatch spacing

HIP:

Hot isostatic press

HT:

Heat treatment

L:

Laser power

L-PBF:

Laser-based-powder bead fusion

LPT:

Low-pressure turbine

OM:

Optical microscope

OM:

Optical microscope

PM:

Powder metallurgy

PSP:

Process structure property

S:

Scanning speed

SEM:

Scanning electron microscope

t:

Layer thickness

TEM:

Transmission electron microscope

TiAl:

Titanium aluminide

UTS:

Ultimate tensile strength

XRD:

X-ray diffraction

at%:

Atomic percent

3D:

Three-dimensional

∆f:

Defocusing distance

α:

Alpha

β:

Beta

γ:

Gamma

C:

Celsius

g:

Gram

h:

Hour

J:

Joule

K:

Kelvin

M:

Mega

m:

meter

mm:

Millimeter

µn:

Micrometer

min:

Minute

Pa:

Pascal

ppm:

Parts per million

s:

Second

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The authors acknowledge the support of the Natural Sciences and Engineering Research Council of Canada (NSERC).

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  1. Department of Mechanical Engineering, McMaster University, 1280 Main Street West, Hamilton, ON, L8S 4L7, Canada

    Hatem A. Soliman & Mohamed Elbestawi

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  1. Hatem A. Soliman
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Hatem A. Soliman: organizing, writing, and editing the manuscript.

M. A. Elbestawi: supervising and revising the manuscript.

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Correspondence to Hatem A. Soliman.

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Soliman, H.A., Elbestawi, M. Titanium aluminides processing by additive manufacturing – a review. Int J Adv Manuf Technol 119, 5583–5614 (2022). https://doi.org/10.1007/s00170-022-08728-w

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