Additive manufacturing of TiAl-based alloys

The ever-increasing demand for developing lightweight, high-temperature materials that can operate at elevated temperatures is still a subject of worldwide research and TiAl-based alloys have come to the fore. The conventional methods of manufacturing have been used successfully to manufacture the TiAl-based alloy. However, due to the inherent limitations of the conventional methods to produce large TiAl components with intricate near-net shapes has limit the widespread application and efficiency of the TiAl components produced using conventional methods. Metal additive manufacturing such as Electron Beam Melting technology could manufacture the TiAl alloys with intricate shapes but lack geometrical accuracy. Laser powder bed fusion (LPBF) technology could manufacture the TiAl-based alloys with intricate shapes with geometrical accuracy. However, the inherent high rate of heating and cooling mechanisms of the LPBF process failed to produce crack-free TiAl components. Various preheating techniques have been experimented, to reduce the high thermal gradient and residual stress during the LPBF process that causes the cracking of the TiAl components. Although these techniques have not reached industrial readiness up to now, encouraging results have been achieved.