Unleashing multi-scale mechanical enhancement in NiTi shape memory alloy via annular intra-laser deposition with homogenized Ti2Ni nanoprecipitates

Additive manufacturing (AM) of composition-sensitive NiTi shape memory alloys (SMAs) is hindered by uncontrollable non-equilibrium microstructures, leading to functional performance degradation and limitations in high-throughput net-shaping applications. To address these challenges, we propose a novel approach combining annular intra-laser directed energy deposition (AIL-DED) with a tailored gradient post-treatment process. This enables the fabrication of nanocomposite microstructures in NiTi SMAs with precise control over the homogenization of Ti ₂Ni nanoprecipitates. In-situ monitoring and characterization of thermal history, microstrain, and constitutional phases, were utilized to uncover the relationship between multi-scale structural features and mechanical responses. The interplay between laser reflectivity, energy input, and lattice thermal vibrations affects forming quality in AIL-DED. Dynamic temperature variations were studied before reaching thermal equilibrium, revealing insights into thermal and mechanical interactions during the process. These findings contribute to understanding challenges in fabricating high-quality NiTi SMAs. Examining phase transformation behavior and its correlation with processing parameters deepens understanding of microstructural evolution and provides insights for tailoring material properties. The stress relaxation and dislocation evacuation at elevated temperatures caused the expansion of lattice and interplanar spacing in the age-treated SMA`s B2 matrix phase, exhibiting a stable two-step phase transformation behavior (B19′↔R↔B2). AIL-DED combined with two-stage heat treatment strategy demonstrated enhanced homogeneity of non-equilibrium microstructures, resulting in the formation of high-density, well-dispersed Ti ₂Ni nanoprecipitates, with a semi-coherent interface to B2 matrix. The combination of load-bearing strengthening through well-dispersed Ti ₂ Ni nanoprecipitates and Orowan strengthening at the semi-coherent interface yielded simultaneous enhancements in nanohardness, ultimate compressive strength, compressive fracture strain, and deformation recovery, following the AIL-DED combined with two-stage heat treatment process. The fracture mechanism transitioned from a mixture of brittle-ductile behavior to predominantly ductile characteristics. This study provides valuable insights that advance additive manufacturing and enhance the functional performance of SMAs in critical applications.