The reduced ductility caused by the brittle needle-like α′ martensite limits the application of TC4 alloys produced by selective laser melting (SLM). Appropriate heat treatment can improve the microstructures and properties of SLM-fabricated TC4 alloys. In this work, SLM-fabricated TC4 alloys underwent stress relief annealing at 600 °C and high-temperature annealing at 800 °C. The effects of heat treatment temperature on phase composition, microstructural morphology, grain orientation, and mechanical properties were investigated. Meanwhile, the microstructural evolution and fracture mechanisms during the heat treatment process were analyzed. The results indicate that after annealing at 600 °C, the needle-like α′ phase transforms into elongated α, and nano-β phase increases. When annealed at 800 °C, the α′ phase completely transforms into a more stable lath-shaped α phase and a short rod-shaped β phase, with the nano-β phase disappearing. The texture orientation gradually shifts from towards , where slip systems are more active. Additionally, heat treatment promotes the transition of grain boundaries to high-angle grain boundaries, thereby alleviating stress concentration and enhancing solid-solution strengthening. After heat treatment, the ultimate tensile strength of the material slightly decreases, but the elongation significantly increases. As the annealing temperature increased, the elongation (EL) improved from 5.22% to 11.43%. Following high-temperature annealing at 800 °C, necking and larger dimples appear on the fracture surface, and the fracture mechanism shifts from a mixed brittle–ductile fracture to a ductile fracture. This work provides a theoretical basis for improving the microstructures and properties of SLM-fabricated TC4 alloys through heat treatment.

Laser direct metal deposition (LDMD) enables not only the preparation of high-performance coatings on the surfaces of low-property materials but also the three-dimensional direct manufacturing and re-manufacturing of parts. In the LDMD process, the spatial coupling characteristics of the powder flow and the laser beam are the key factors affecting the forming quality of the cladding layer. Based on the gas–solid two-phase flow theory, a numerical model of coaxial powder feeding was established by CFD. The powder flow characteristics of the lower part of the nozzle, the powder particle motion trajectory, and the optical-powder spatial coupling morphology and law were studied, and the relationship between the powder flow morphology, laser beam, and powder utilization was explored. On this basis, the law between the optical-powder coupling characteristics and the geometric characteristics of the cladding layer is discussed in conjunction with LDMD experiments. The results show that the powder concentration scalar located in the focal plane of the laser beam can be used to visualize the optical-powder coupling morphology. When the powder feeding speed exceeds the loading capacity of the carrier gas flow, the powder concentration in the center of the spot and the powder utilization rate decrease. When the carrier gas flow rate is 4.0 L/min and the powder feeding rate is 4.0 g/min, the best utilization rate achieved is 81.4%. In addition, the H (height) of the cladding layer is more sensitive to changes in the powder concentration than the W (width). These findings provide new ideas for nozzle structure design and the optimization of LDMD parameters.