Microstructure, microhardness, tensile and fatigue investigation on laser shock peened Ti6Al4V manufactured by high layer thickness directed energy deposition additive manufacturing

Thin layer thickness in additive manufacturing (AM) has always been a hindering factor leading to long completion times. Increasing layer thickness is accompanied by a higher tendency of surface cracks and inferior mechanical properties. These can be improved with laser shock peening (LSP). Emphasizing on the high layer thickness, this paper elucidates the high-layer thickness laser directed energy deposition (LDED) AM and the effects of LSP on the fabricated parts. Primary focus was given to the investigation of surface microcracks, microstructures, tensile and fatigue properties. Ti6Al4V bulk sample was prepared using the LDED process. Tensile, fatigue, and other samples were extracted to investigate the above-mentioned properties using different characterization tools such as optical microscope, scanning electron microscope, Vickers microhardness tester, and universal testing machine. Results showed proper depositions without major defects despite the high-layer thickness. Micro-cracks were limited to the surface only, and typical Widmansta<spacing diaeresis>tten patterns with parallel alpha lath and mixed alpha+beta microstructures are observed. Yield strength (YS) varied from 730 MPa to 940 MPa, while ultimate tensile strength (UTS) ranged from 799.5 MPa to 953.75 MPa. Even though laser peening significantly improved micro-hardness by 49.81 % on average, not all fatigue samples observed enhanced fatigue life. A maximum improvement of 40.34 % in fatigue performance was observed in the LDED+LSPed samples. The strain hardening, plastic deformation, and grain refinement during the LSP process contributed to the enhanced mechanical properties. Some samples' reduced fatigue life may be due to the anisotropic nature of additively manufactured parts, internal defects, and surface cracks on the specific samples. Considering high layer thickness, vertical orientation of samples, and as-prepared samples, our research shows a promising high layer thickness additive manufacturing process. The current research can be used as a base for further study on other properties and characteristics.