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<p>Understanding the influence of Electron Beam Melting (PBF-EB) process parameters on processing the Ti-55511 titanium alloy is essential for optimizing its microstructure and mechanical properties, improving process stability, and ensuring the reliability of components intended for automotive and aerospace applications. The manufacturing parameters of the Electron Beam Melting (PBF-EB) process, mainly volume energy and beam speed, strongly influence the thermal history, internal defect formation, and chemical composition of the alloy, and thus significantly affect α/β phase evolution, microstructure, and mechanical properties of metastable, near-β titanium alloys. Changes in these parameters can affect the resulting microstructure and properties. This study investigates the effects of beam speed and volume energy on the Ti-55511 alloy. The analysis included relative density, chemical and phase composition, porosity, hardness, and mechanical performance. The results of this study indicate that higher beam speeds reduce thermal gradients, enhancing aluminium evaporation and promoting the formation of coarser α-phase plates, which leads to reduced hardness due to microstructural coarsening and an increase in elongation. Low volume energy (20&#xa0;J/mm³) decreases relative density by introducing gas pores, columnar pores, and lack-of-fusion defects, while 30&#xa0;J/mm³ or higher, combined with moderate beam speeds, yields components with high density and a favourable balance of strength and ductility. Overall, the findings highlight the critical role of process parameters—beam speed and energy density—in controlling microstructural evolution and mechanical behaviour in PBF-EB manufactured Ti-55511 components.</p>

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Microstructural evolution and mechanical properties of Ti-55511 alloy produced by electron beam melting: role of volume energy density and beam speed

  • 期刊论文

  • 发表日期：

    2026年3月16日

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  • Marcin Madeja,
  • Robert Dziedzic

摘要

Understanding the influence of Electron Beam Melting (PBF-EB) process parameters on processing the Ti-55511 titanium alloy is essential for optimizing its microstructure and mechanical properties, improving process stability, and ensuring the reliability of components intended for automotive and aerospace applications. The manufacturing parameters of the Electron Beam Melting (PBF-EB) process, mainly volume energy and beam speed, strongly influence the thermal history, internal defect formation, and chemical composition of the alloy, and thus significantly affect α/β phase evolution, microstructure, and mechanical properties of metastable, near-β titanium alloys. Changes in these parameters can affect the resulting microstructure and properties. This study investigates the effects of beam speed and volume energy on the Ti-55511 alloy. The analysis included relative density, chemical and phase composition, porosity, hardness, and mechanical performance. The results of this study indicate that higher beam speeds reduce thermal gradients, enhancing aluminium evaporation and promoting the formation of coarser α-phase plates, which leads to reduced hardness due to microstructural coarsening and an increase in elongation. Low volume energy (20 J/mm³) decreases relative density by introducing gas pores, columnar pores, and lack-of-fusion defects, while 30 J/mm³ or higher, combined with moderate beam speeds, yields components with high density and a favourable balance of strength and ductility. Overall, the findings highlight the critical role of process parameters—beam speed and energy density—in controlling microstructural evolution and mechanical behaviour in PBF-EB manufactured Ti-55511 components.