Recent Advancements in Microstructure Control and Performance Optimization of Titanium Alloys via Powder Bed Fusion

The advent of powder bed fusion (PBF) technology marked a significant development in metal additive manufacturing (AM), offering unrivaled design flexibility, precision, and deposition rates. This review examines the intricacies of the PBF process, with a particular emphasis on titanium (Ti) and its alloys (Ti‐alloys). Although the microstructural evolution under various PBF conditions has been extensively studied, the unique advantages of PBF in alloy design and processing remain underexplored. It systematically compares the performance characteristics of Ti‐alloys fabricated via laser and electron beam technologies, with a particular focus on their forming properties, microstructure, and mechanical properties. Key challenges hindering the progress of PBFs, along with potential solutions, are identified. In addition, it explores the unique processing characteristics of PBF and advocate innovative alloy design to achieve superior microstructures and properties not possible with conventional methods. This study's findings provide important insights and future directions for optimizing Ti‐alloys development through PBF, paving the way for further development of PBF and Ti‐alloys.