Titanium alloys have become key materials for high-performance lightweight components, particularly in the aerospace sector. In combination with additive manufacturing technologies, they enable the production of complex, functionally optimized structures that offer both high performance and efficient material utilization.

In our research activities, we investigate the processing of the metastable beta titanium alloy Ti-5Al-5V-5Mo-3Cr (Ti-5553) using laser powder bed fusion (PBF-LB/M). This alloy provides an exceptional strength-to-weight ratio, while simultaneously imposing high demands on process control and subsequent machining.

The extreme solidification conditions during the PBF-LB/M process lead to microstructures in Ti-5553 that differ significantly from those obtained through conventional manufacturing routes. In particular, nearly fully beta microstructures can form, whose properties are strongly influenced by the selected process parameters and subsequent heat treatments. These microstructural variants exhibit different behavior during machining, which is reflected, for example, in tool wear and achievable surface quality.

A central focus of our work is therefore the targeted adjustment of microstructures that enhance both mechanical properties and machinability. By varying laser parameters and developing suitable heat treatment strategies, microstructural states can be generated that enable more efficient post-processing. This opens up new possibilities for the production of functionally graded titanium components, in which local properties can be tailored to specific loading conditions.

Our work contributes to making Ti-5553 more economically viable for additive manufacturing while significantly reducing tool wear, post-processing time, and material consumption. In doing so, it supports a more resource-efficient production of high-performance components.

We gratefully acknowledge the support of the German Research Foundation (DFG) for funding this project. (Projekt-ID: 432764611)