Investigation on the relationships among process parameters, molten pool characteristics, and fabrication quality of Ti-10V-2Fe-3Al by laser direct energy deposition

Ti-10 V-2Fe-3Al (Ti-1023) titanium alloy is a metastable high-strength β titanium alloy. Defects such as spatters, pores, and poor surface quality tend to occur during the laser direct energy deposition (LDED) of Ti-1023 titanium alloys, prohibiting its large-scale engineering application. Therefore, to obtain high-quality LDED of Ti-1023 titanium alloy, this study used a regression analysis model to investigate the relationship between key process parameters and the geometrical characteristics of single clad tracks to obtain the forming process map. In addition, an off-axis high-speed camera was used to monitor the forming process of the Ti-1023 titanium alloy single clad tracks, and the correlation between the forming quality of the three types of forming conditions—namely incomplete melting, normal melting, and over-melting—and the characteristics of the molten pool was analyzed. Finally, this study established a simplified relationship between the process parameters, the molten pool characteristics, and fabrication quality of LDED of Ti-1023 titanium alloy, which is expected to improve development for the online monitoring and increase the application of LDED Ti-1023 titanium alloy.