The effect of multiple thermal cycles on Ti-6Al-4V deposits fabricated by wire-arc directed energy deposition: Microstructure evolution, mechanical properties, and corrosion resistance

Thermal cycles have an important effect on the microstructure and properties of the components fabricated by wire-arc directed energy deposition (wire-arc DED). In this study, a Gleeble thermal-mechanical simulator was adopted to create closer-to-reality thermal cycles with the assistance of a numerical simulation model and experimental Ti-6Al-4V deposition. Step-by-step microstructure evolution, including α_m, retained β, and GB α, microhardness gradual variation, and the corrosion resistance change before and after the entire thermal cycle were investigated. Therefore, combining phase orientation and high-magnification morphology, transformed and untransformed α that occurred in low- and medium-temperature thermal cycles can be distinguished. After the entire thermal cycle, α_m laths coarsened from ∼1 µm to ∼1.2 µm, and the content of retained β phase became more and more. The α_m formed around grain boundaries partially disappeared and was occupied by α laths from the inner grain. GB α was more continuously distributed along prior β grain boundaries due to its lower formation temperature during the subsequent thermal cycles that were occurring incomplete α→β transformation. The severe preferential orientation of α phases formed after the deposition and high-temperature thermal cycle was also alleviated through the twice low-temperature thermal cycles. Besides, the microhardness decreased from 318.78 ± 7.5 HV to 285.17 ± 5.3 HV after the high-temperature thermal cycle but eventually increased significantly to 330.5 ± 6.4 HV after experiencing the final low-temperature thermal cycle. The corrosion resistance decreased after the entire thermal cycle, indicating a performance difference between the top and bottom regions of the Ti-6Al-4 V component fabricated by wire-arc DED.