Development of crack-free functionally graded Ti64/TNM-B1 material using laser powder bed fusion

The processing of Titanium Aluminides (TiAls) and Ti64 significantly benefits aerospace applications due to their excellent strength-to-weight ratio. Ti64 is commonly used for turbine disks, while TiAl is utilized for low-pressure blades. Laser Powder Bed Fusion (L-PBF) can facilitate the seamless integration of these materials, where reducing connections is essential for weight savings. However, challenges remain, such as variations in thermal expansion coefficients and the potential for crack formation during L-PBF. This study develops a functional graded material from Ti64 to TNM-B1 in 20 % increments, for the first time using L-PBF without cracks, followed by post-processing to enhance the microstructure.