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<p>Integrating microscale mechanical mapping with microstructural and residual-stress analysis provides a robust approach to establishing process–structure–property relationships at a fine scale in additively manufactured (AM) metals. This study examines the microscale mechanical response of Ti-6Al-4V fabricated by laser powder bed fusion (PBF-LB), followed by hot isostatic pressing (HIP) as a post-process, alongside a wrought (WR) sample as a baseline reference for wrought material. Microstructural and nanoindentation mapping, combined with porosity analysis, showed that the as-printed (AP) samples exhibited higher hardness (5.74 GPa), which correlates with the presence of a fine α′ martensitic microstructure, despite a relatively higher porosity level (1.927%). HIP reduced porosity to 0.014% and transformed the microstructure to a coarsened α + β phase, yielding a comparable average hardness of 5.61 GPa. The WR condition displayed negligible porosity, a fine equiaxed α + β microstructure, and the lowest hardness (4.79 GPa). A coefficient of variation (CV%) analysis further revealed greater hardness variability in HIP than in AP, attributable to their differing β-phase fractions. Residual stress measurements indicated high tensile stress in AP (0.275 GPa), a uniform, near-stress-free state with minimal tensile stress in HIP (~ 0.02 GPa), and moderate tensile stress in WR (0.129 GPa). The experimental results fell within the simulated range, reflecting trend alignment between the two approaches. Both experimental and simulated residual stress indicate similar behavior across processing conditions, while combined nanoindentation–EBSD mapping is used to assess spatial variations in microscale mechanical response relative to microstructural features.</p>

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Correlating microstructure and residual stress improvement in HIP-processed PBF-LB Ti-6Al-4V using nanoindentation property mapping

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月10日

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  • Lutfun Nipa,
  • Darshpreet Kaur Saini,
  • Bibhudutta Rout,
  • Hector R. Siller

摘要

Integrating microscale mechanical mapping with microstructural and residual-stress analysis provides a robust approach to establishing process–structure–property relationships at a fine scale in additively manufactured (AM) metals. This study examines the microscale mechanical response of Ti-6Al-4V fabricated by laser powder bed fusion (PBF-LB), followed by hot isostatic pressing (HIP) as a post-process, alongside a wrought (WR) sample as a baseline reference for wrought material. Microstructural and nanoindentation mapping, combined with porosity analysis, showed that the as-printed (AP) samples exhibited higher hardness (5.74 GPa), which correlates with the presence of a fine α′ martensitic microstructure, despite a relatively higher porosity level (1.927%). HIP reduced porosity to 0.014% and transformed the microstructure to a coarsened α + β phase, yielding a comparable average hardness of 5.61 GPa. The WR condition displayed negligible porosity, a fine equiaxed α + β microstructure, and the lowest hardness (4.79 GPa). A coefficient of variation (CV%) analysis further revealed greater hardness variability in HIP than in AP, attributable to their differing β-phase fractions. Residual stress measurements indicated high tensile stress in AP (0.275 GPa), a uniform, near-stress-free state with minimal tensile stress in HIP (~ 0.02 GPa), and moderate tensile stress in WR (0.129 GPa). The experimental results fell within the simulated range, reflecting trend alignment between the two approaches. Both experimental and simulated residual stress indicate similar behavior across processing conditions, while combined nanoindentation–EBSD mapping is used to assess spatial variations in microscale mechanical response relative to microstructural features.