Additive Manufacturing (AM) technology is capable of building 3D near-net-shaped functional parts directly from computer models, using unit materials, such as powder or wire. AM offers superior geometrical flexibility with significantly reduced manufacturing lead time, energy, and material waste. These benefits make AM desirable for critical transportation applications, providing that structural integrity and performance requirements are met or exceeded. In this study, structural materials fabricated by two AM techniques were investigated: Laser Engineered Net Shaping (LENS) and Electron Beam Melting (EBM). Ti-6Al-4V alloys were produced using both methods and various processing conditions, which resulted in different microstructures and mechanical properties given their unique thermal histories. Characteristic microstructures were determined for all cases. Room temperature tensile and fatigue crack growth (FCG) properties were also evaluated and compared in different orientations with respect to the deposition direction. The effects of post-deposition heat treatment on tensile and FCG properties were determined. The results are systematically presented and discussed from both the material/process optimization, as well as structural design and fatigue life prediction perspectives

The use of secondary aluminum alloys in industry is still limited by the high Fe contents in recycled alloys. In general, the Fe-rich intermetallic compounds deteriorate the performance of secondary Al-Si alloys, specially the β-Fe phase. To mitigate the detrimental effects of iron, the influence of diferent cooling rates and holding temperatures on the modification and purification of iron-rich compounds in commercial AlSi10MnMg alloy with 1.1 wt % Fe was studied. According to the results obtained by CALPHAD calculations, the alloy was modified by adding a 0.7 wt%, 1.2 wt%. and 2.0 wt% of Mn. The phase formation and morphology of iron-rich compounds was systematically studied and correlated by different microstructural characterization techniques. The experimental results showed that the detrimental β-Fe phase can be avoided by adding at least 1.2 wt % of Mn at the studied cooling rates. Finally, the effect of different holding temperatures in the sedimentation of Fe-rich compounds also was studied. Hence, the gravitational sedimentation experiments at different holding times and temperatures were conducted to validate the feasibility of the methodology in different processing conditions. The experimental results showed a high Fe removal efficiency up to 64% and 61%, after a holding time of 30 min at 600 °C and 670 °C, respectively. The addition of Mn improved the Fe removal efficiency but not gradually, as the best results were obtained in the alloy containing 1.2 wt % Mn.