Titanium aluminides processing by additive manufacturing – a review

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.