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<p>This study systematically compares laser powder bed fusion processing of plasma-spheroidized (PS) and gas-atomized (GA) Ti-6Al-4V powders. Results demonstrate that the GA powder achieves the highest relative density of 99.14% at a volumetric energy density of 55.56&#xa0;J/mm<sup>3</sup> while PS powder requires a higher energy input of 59.26&#xa0;J/mm<sup>3</sup> to obtain the highest relative density of 98.83% due to enhanced laser absorptivity of surface nanoparticles, which contribute to spattering and porosity defects. Microstructural analysis reveals that LPBF-ed PS samples develop coarser grains, a higher fraction of low-angle grain boundaries, and stronger α′-phase texture along the &lt; 11–20 &gt; direction compared to LPBF-ed GA samples. Mechanically, the LPBF-ed PS samples show a highest ultimate tensile strength of 1202.7&#xa0;MPa, outperforming 1121.9&#xa0;MPa of the gas-atomized samples. However, it exhibits only 4.51% elongation due to higher oxygen content and dislocation entanglement, a value markedly lower than the 15.96% in LPBF-ed GA samples.</p> Graphical Abstract <p></p>

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Microstructure and Mechanical Properties of Ti-6Al-4V Fabricated by Laser Powder Bed Fusion Using Plasma-Spheroidized and Gas-Atomized Powders

  • 期刊论文

  • 发表日期：

    2026年2月26日

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  • Yunfei Liu,
  • Zhenhua Hao,
  • Rulong Ma,
  • Yongchun Shu,
  • Jilin He

摘要

This study systematically compares laser powder bed fusion processing of plasma-spheroidized (PS) and gas-atomized (GA) Ti-6Al-4V powders. Results demonstrate that the GA powder achieves the highest relative density of 99.14% at a volumetric energy density of 55.56 J/mm3 while PS powder requires a higher energy input of 59.26 J/mm3 to obtain the highest relative density of 98.83% due to enhanced laser absorptivity of surface nanoparticles, which contribute to spattering and porosity defects. Microstructural analysis reveals that LPBF-ed PS samples develop coarser grains, a higher fraction of low-angle grain boundaries, and stronger α′-phase texture along the < 11–20 > direction compared to LPBF-ed GA samples. Mechanically, the LPBF-ed PS samples show a highest ultimate tensile strength of 1202.7 MPa, outperforming 1121.9 MPa of the gas-atomized samples. However, it exhibits only 4.51% elongation due to higher oxygen content and dislocation entanglement, a value markedly lower than the 15.96% in LPBF-ed GA samples.

Graphical Abstract