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<p>This study presents a multiscale evaluation of the effects of various post-processing strategies, including machining, shot peening (SP), and heat treatment, on the static bending behavior of Ti6Al4V alloy produced by selective laser melting (SLM). Five specimen groups were prepared: as-built, milled, milled followed by traditional SP, milled followed by dual SP, and annealed before milling. To establish a detailed structure–property relationship, the study integrates surface roughness measurements, microstructural and fracture surface characterizations with three-point bending tests. Milling significantly improved surface quality, reducing the average surface roughness (<i>R</i><sub>a</sub>) from 17.05&#xa0;μm in the as-built specimens to 0.43&#xa0;μm in the only machined ones. This significant reduction contributed to higher bending strength and bending strain compared with the as-built specimens. While conventional SP slightly increased the surface roughness amplitude (<i>R</i><sub>a</sub>, <i>R</i><sub>z</sub>, and <i>R</i><sub>c</sub>), the secondary SP with smaller-diameter shots reduced roughness amplitude again and resulted in a more homogeneous surface topography. Machining alone improved bending strength by 23%, whereas dual SP yielded the highest strength with a 34% increase relative to the as-built specimens, due to induced compressive residual stresses, martensitic α′ lath refinement, reduced surface roughness, and higher dislocation density. Heat treatment transformed the martensitic α′ phase in prior β grains into an α + β structure, and the annealed and machined specimens exhibited a 264% increase in bending strain relative to the as-built specimens and 184% compared to the only machined specimens, with ductility enhancement primarily governed by the α + β transformation and supported by reduced surface roughness.</p>

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Post-processing-induced improvements in the bending behavior of SLM-produced Ti6Al4V alloy

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年2月17日

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  • Sinan Önder,
  • Nurşen Saklakoğlu,
  • Ahmet Sever,
  • Gökhan Başar

摘要

This study presents a multiscale evaluation of the effects of various post-processing strategies, including machining, shot peening (SP), and heat treatment, on the static bending behavior of Ti6Al4V alloy produced by selective laser melting (SLM). Five specimen groups were prepared: as-built, milled, milled followed by traditional SP, milled followed by dual SP, and annealed before milling. To establish a detailed structure–property relationship, the study integrates surface roughness measurements, microstructural and fracture surface characterizations with three-point bending tests. Milling significantly improved surface quality, reducing the average surface roughness (Ra) from 17.05 μm in the as-built specimens to 0.43 μm in the only machined ones. This significant reduction contributed to higher bending strength and bending strain compared with the as-built specimens. While conventional SP slightly increased the surface roughness amplitude (Ra, Rz, and Rc), the secondary SP with smaller-diameter shots reduced roughness amplitude again and resulted in a more homogeneous surface topography. Machining alone improved bending strength by 23%, whereas dual SP yielded the highest strength with a 34% increase relative to the as-built specimens, due to induced compressive residual stresses, martensitic α′ lath refinement, reduced surface roughness, and higher dislocation density. Heat treatment transformed the martensitic α′ phase in prior β grains into an α + β structure, and the annealed and machined specimens exhibited a 264% increase in bending strain relative to the as-built specimens and 184% compared to the only machined specimens, with ductility enhancement primarily governed by the α + β transformation and supported by reduced surface roughness.