Optimization of process parameters to produce Ti6242 parts via DED process

Titanium alloys in last decades have caught on large use in aerospace, biomedical and motorsport fields due to their peerless strength-weight ratio, corrosion resistance and toughness. The Ti-6Al-2Sn-4Zr-2Mo (Ti6242) enhance further application with respect to the most common Ti-6Al-4V, with higher maximum temperature of exercise (540°C). However, the machinability of this alloy is demanding, and additive manufacturing provides a possible reduction of tool usage, with the possibility to build by addition instead of subtraction as traditional technology are used to. For this reason, this thesis aims to find some suitable parameters for the Ti6242, by directed energy deposition (DED), through a process of parameter optimization by steps. Starting from a family of the most relevant parameters, single tracks are analysed to find the best combination; with single wall and single layer analysis also hatching and z-step have been optimized and as a final stage cubes as representative parts have been built up and analysed. Finally cubes undergo cross section analysis and tomography to evaluate parts final density, while microstructure analysis is detected through chemical etching.