Additive manufacturing of Ti-6Al-4V using pre-calcined powder: Simple pretreatment for exceptional 1410 MPa high yield strength

Chuntao Zhou; Weipeng Li; Dawei Wang; Yanhong Tian; Yinghao Zhou; Tao Yang; Jian Zhang; Ming Yan

doi:10.1016/j.msea.2025.148573

Additive manufacturing of Ti-6Al-4V using pre-calcined powder: Simple pretreatment for exceptional 1410 MPa high yield strength

Chuntao Zhou (Co-first Author), Weipeng Li (Co-first Author), Dawei Wang, Yanhong Tian, Yinghao Zhou, Tao Yang, Jian Zhang^*, Ming Yan^*

^*Corresponding author for this work

Department of Materials Science and Engineering

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

3 Citations (Scopus)

Abstract

To achieve excellent combination of strength-ductility for titanium alloys, an innovative and scalable feedstock pretreatment by calcination in nitrogen gas has been incorporated into the additive manufacturing process. Utilizing the pre-calcined powder, Ti-6Al-4V (Ti64) demonstrates an yield strength of 1410 MPa, ultimate tensile strength of 1462 MPa, and an elongation of 8.12 % through powder bed fusion-laser beam (PBF-LB) process, surpassing previously reported Ti64 alloys prepared via traditional methods or PBF-LB. Microstructure analyses using transmission electron microscopy and atom probe tomography indicate that solution strengthening and fine grain strengthening contribute to the exceptional high strength primarily.

© 2025 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies.

Original language	English
Article number	148573
Journal	Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing
Volume	941
Online published	26 May 2025
DOIs	https://doi.org/10.1016/j.msea.2025.148573
Publication status	Published - Sept 2025

Funding

This work was supported by the National Natural Science Foundation of China [No. 52271032], the State Key Laboratory of Advanced Welding and Joining [AWJ-22M01], the Natural Science Foundation of Guangdong Province [2020A1515011373], Shenzhen Science and Technology Innovation Commission [No. JCYJ20220818100612027], and Shenzhen Medical Research Fund [D2402016]. The authors would like to acknowledge the technical support from SUSTech CRF. Atom probe tomography research was conducted at the Inter-University 3D Atom Probe Tomography Unit of City University of Hong Kong, which is supported by the CityU grant 9360161.

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 9 Industry, Innovation, and Infrastructure

Research Keywords

Powder bed fusion-laser beam
Pre-calcined Ti-6Al-4V powder
Solution strengthening
Fine grain strengthening

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10.1016/j.msea.2025.148573

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Zhou, C., Li, W., Wang, D., Tian, Y., Zhou, Y., Yang, T., Zhang, J., & Yan, M. (2025). Additive manufacturing of Ti-6Al-4V using pre-calcined powder: Simple pretreatment for exceptional 1410 MPa high yield strength. Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing, 941, Article 148573. https://doi.org/10.1016/j.msea.2025.148573

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title = "Additive manufacturing of Ti-6Al-4V using pre-calcined powder: Simple pretreatment for exceptional 1410 MPa high yield strength",

abstract = "To achieve excellent combination of strength-ductility for titanium alloys, an innovative and scalable feedstock pretreatment by calcination in nitrogen gas has been incorporated into the additive manufacturing process. Utilizing the pre-calcined powder, Ti-6Al-4V (Ti64) demonstrates an yield strength of 1410 MPa, ultimate tensile strength of 1462 MPa, and an elongation of 8.12 % through powder bed fusion-laser beam (PBF-LB) process, surpassing previously reported Ti64 alloys prepared via traditional methods or PBF-LB. Microstructure analyses using transmission electron microscopy and atom probe tomography indicate that solution strengthening and fine grain strengthening contribute to the exceptional high strength primarily.{\textcopyright} 2025 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies.",

keywords = "Powder bed fusion-laser beam, Pre-calcined Ti-6Al-4V powder, Solution strengthening, Fine grain strengthening",

author = "Chuntao Zhou and Weipeng Li and Dawei Wang and Yanhong Tian and Yinghao Zhou and Tao Yang and Jian Zhang and Ming Yan",

year = "2025",

month = sep,

doi = "10.1016/j.msea.2025.148573",

language = "English",

volume = "941",

journal = "Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing",

issn = "0921-5093",

publisher = "Elsevier Ltd.",

}

Additive manufacturing of Ti-6Al-4V using pre-calcined powder: Simple pretreatment for exceptional 1410 MPa high yield strength. / Zhou, Chuntao (Co-first Author); Li, Weipeng (Co-first Author); Wang, Dawei et al.
In: Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing, Vol. 941, 148573, 09.2025.

Research output: Journal Publications and Reviews › RGC 21 - Publication in refereed journal › peer-review

TY - JOUR

T1 - Additive manufacturing of Ti-6Al-4V using pre-calcined powder

T2 - Simple pretreatment for exceptional 1410 MPa high yield strength

AU - Zhou, Chuntao

AU - Li, Weipeng

AU - Wang, Dawei

AU - Tian, Yanhong

AU - Zhou, Yinghao

AU - Yang, Tao

AU - Zhang, Jian

AU - Yan, Ming

PY - 2025/9

Y1 - 2025/9

N2 - To achieve excellent combination of strength-ductility for titanium alloys, an innovative and scalable feedstock pretreatment by calcination in nitrogen gas has been incorporated into the additive manufacturing process. Utilizing the pre-calcined powder, Ti-6Al-4V (Ti64) demonstrates an yield strength of 1410 MPa, ultimate tensile strength of 1462 MPa, and an elongation of 8.12 % through powder bed fusion-laser beam (PBF-LB) process, surpassing previously reported Ti64 alloys prepared via traditional methods or PBF-LB. Microstructure analyses using transmission electron microscopy and atom probe tomography indicate that solution strengthening and fine grain strengthening contribute to the exceptional high strength primarily.© 2025 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies.

AB - To achieve excellent combination of strength-ductility for titanium alloys, an innovative and scalable feedstock pretreatment by calcination in nitrogen gas has been incorporated into the additive manufacturing process. Utilizing the pre-calcined powder, Ti-6Al-4V (Ti64) demonstrates an yield strength of 1410 MPa, ultimate tensile strength of 1462 MPa, and an elongation of 8.12 % through powder bed fusion-laser beam (PBF-LB) process, surpassing previously reported Ti64 alloys prepared via traditional methods or PBF-LB. Microstructure analyses using transmission electron microscopy and atom probe tomography indicate that solution strengthening and fine grain strengthening contribute to the exceptional high strength primarily.© 2025 Elsevier B.V. All rights are reserved, including those for text and data mining, AI training, and similar technologies.

KW - Powder bed fusion-laser beam

KW - Pre-calcined Ti-6Al-4V powder

KW - Solution strengthening

KW - Fine grain strengthening

UR - https://www.webofscience.com/wos/woscc/full-record/WOS:001504109100001

U2 - 10.1016/j.msea.2025.148573

DO - 10.1016/j.msea.2025.148573

M3 - RGC 21 - Publication in refereed journal

SN - 0921-5093

VL - 941

JO - Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing

JF - Materials Science & Engineering A: Structural Materials: Properties, Microstructure and Processing

M1 - 148573

ER -

Additive manufacturing of Ti-6Al-4V using pre-calcined powder: Simple pretreatment for exceptional 1410 MPa high yield strength

Abstract

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UN SDGs

Research Keywords

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ResFac: Inter-University 3D Atom Probe Tomography Unit

Cite this

Additive manufacturing of Ti-6Al-4V using pre-calcined powder: Simple pretreatment for exceptional 1410 MPa high yield strength

Abstract

Funding

UN SDGs

Research Keywords

Access Output

Other Access Options

Permanent Link

Other Files and Links

Fingerprint

Projects

ResFac: Inter-University 3D Atom Probe Tomography Unit

Cite this