Layer-by-layer manufacturing of titanium plate: fabrication, microstructure, mechanical, and numerical prediction of tensile test

This study presents a comprehensive investigation into the microstructural evolution, crystallographic texture, and mechanical performance of commercially pure titanium (Ti CP-Grade 2) fabricated using TIG-aided Layer-by-Layer Manufacturing (LLM). The fabricated plate exhibited a defect-free, equiaxed microstructure dominated by acicular and serrated α-laths, which contributed significantly to its mechanical strength. Texture analysis revealed a strong α-phase alignment ({0001}), indicating a direct influence of thermal history on grain orientation and material integrity. The presence of α, β, and α + β phases confirmed through X-ray diffraction was found to govern the enhanced tensile strength, hardness, and impact resistance compared to wrought titanium. Furthermore, finite element simulations demonstrated excellent agreement with experimental tensile data, validating the predictive accuracy of the mechanical behaviour based on electron backscatter diffraction spectroscopy -derived texture and phase composition. These findings establish a robust framework for the predictive design and performance optimization of titanium components in advanced engineering application.