The Ti–35Nb–7Zr–5Ta (wt%, TNZT) alloy was reinforced with TiB₂ and synthesized by L-PBF. The relatively small TiB₂ particles change the solidification structure from cellular to columnar-dendritic and lead to submicron TiB precipitation in the β matrix. This results in pronounced grain refinement and reduction of texture. However, the microstructure of the additively manufactured TNZT-TiB₂ is still different from the as-cast, unreinforced TNZT, which contains equiaxed and randomly oriented grains. The β phase is less stable in the as-cast samples, leading to stress-induced martensitic transformation and recoverable strain of 1.5%. The TNZT with 1 wt% of TiB₂ presents significantly higher compressive strength (σ_YS = 495 MPa) compared to unreinforced samples (σ_YS = 430 MPa), without sacrificing ductility or altering Young’s modulus (E ≈ 46 GPa). The addition of a small fraction of TiB₂ to the TNZT alloy synthesized by L-PBF is a promising alternative for manufacturing sophisticated components for biomedical applications. Graphical abstract

The influence of scanning strategy (SS) on microstructure and mechanical properties of a Ti–35Nb–7Zr–5Ta alloy processed by laser-powder bed fusion (L-PBF) is investigated for the first time. Three SSs are considered: unidirectional-Y; bi-directional with 79° rotation (R79); and chessboard (CHB). The SSs affect the type and distribution of pores. The highest relative densities and more homogeneous distribution of pores are obtained with R79 and CHB scanning strategies, whereas aligned pores are formed in the unidirectional-Y. The SSs show direct influence on the crystallographic texture with unidirectional-Y strategy showing fiber texture. The R79 strategy results in a weak texture and the CHB scanning strategy forms a randomly oriented heterogeneous grain structure. The lowest Young modulus is obtained with the unidirectional-Y strategy, whereas the R79 strategy results in the highest yield strength. It is shown that the SSs may be used for tuning the microstructure of a beta-Ti alloy in L-PBF. Graphical abstract

This work presents a new eddy current testing array probe and readout electronics that target the layer-wise quality control in powder bed fusion metal additive manufacturing. The proposed design approach brings important benefits to the sensors’ number scalability, exploring alternative sensor elements and minimalist signal generation and demodulation. Small-sized, commercially available surface-mounted technology coils were evaluated as an alternative to usually employed magneto-resistive sensors, demonstrating low cost, design flexibility, and easy integration with the readout electronics. Strategies to minimize the readout electronics were proposed, considering the specific characteristics of the sensors’ signals. An adjustable single phase coherent demodulation scheme is proposed as an alternative to traditional in-phase and quadrature demodulation provided that the signals under measurement showed minimal phase variations. A simplified amplification and demodulation frontend using discrete components was employed together with offset removal, vector amplification, and digitalization implemented within the microcontrollers’ advanced mixed signal peripherals. An array probe with 16 sensor coils and a 5 mm pitch was materialized together with non-multiplexed digital readout electronics, allowing for a sensor frequency of up to 1.5 MHz and digitalization with 12 bits resolution, as well as a 10 kHz sampling rate.

This paper presents the development of a novel eddy current array (ECA) system for real-time, layer-by-layer quality control in powder bed fusion (PBF) additive manufacturing. The system is integrated into the recoater of a PBF machine to provide spatially resolved electrical conductivity imaging of the manufactured part. The system features an array of 40 inductive sensors spaced at 1 mm pitch and is capable of performing a full array readout every 0.192 mm at 100 mm/s recoater speed. Array scalability was achieved through the careful selection of the electromagnetic configuration, miniaturized and seamlessly integrated sensor elements, and the use of advanced mixed signal processing techniques. Experimental validation was performed on stainless steel 316L parts, successfully detecting metallic structures and confirming system performance in both laboratory and real-time PBF environments. The prototype achieved a signal-to-noise ratio (SNR) of 26.5 dB, discriminating metal from air and thus demonstrating its potential for improving PBF part design, process optimization, and defect detection.