The potential for grain refinement of Wire-Arc Additive Manufactured (WAAM) Ti-6Al-4V by ZrN and TiN inoculation

Wire-Arc Additive Manufacturing (WAAM) of large near-net-shape titanium components has the potential to reduce costs and lead-time in many industrial sectors including aerospace. However, with titanium alloys, such as Ti-6Al-4V, standard WAAM processing conditions result in solidification microstructures comprising large cm-scale, <001> fibre textured, columnar beta grains, which are detrimental to mechanical performance. In order to reduce the size of the solidified beta-grains, as well as refine their columnar morphology and randomise their texture, two cubic nitride phases, TiN and ZrN were investigated as potential grain refining inoculants. To avoid the cost of manufacturing new wire, experimental trials were performed using powder adhered to the surface of the deposited tracks. With TiN particle additions, the beta grain size was successfully reduced and modified from columnar to equiaxed grains, with an average size of 300 mu m, while ZrN powder was shown to be ineffective at low addition levels studied. Clusters of TiN particles were found to be responsible for nucleating multiple beta Ti grains. By utilizing the Burgers orientation relationship, EBSD investigation showed that a Kurdjumov-Sachs orientation relationship could be demonstrated between the refined primary beta grains and TiN particles.