Role of Ti-6Al-4V addition in modulating crack sensitivity, solidification microstructure and mechanical properties of laser powder bed fused γ-TiAl alloys

Solidification cracking is still the primary challenge for laser powder bed fusion (LPBF) without high-temperature preheating of gamma-TiAl alloys. Circumventing the peritectic reaction and promoting beta-solidification by adding the beta-stablizing elements have been proved to be an effective way to suppressing the crack formation. In this work, we attempted a more economic method to realize beta-solidification via the addition of Ti-6Al-4V (TC4) pre-alloyed powder. The results showed that the TC4 addition successfully changed the solidification path from L -> L+beta -> L+alpha ->alpha ->alpha+gamma ->alpha 2+gamma to L -> L+beta ->beta ->alpha+beta ->alpha 2+beta/B2. As a result, the solidified microstructure was mainly comprised of primary alpha 2 phase and small amount of retained beta/B2 (8.5 %) phase distributed along the molten pool boundary. What's more important was that the TC4 addition led to a 44.6 % decrease in crack density. Contributions to low hot cracking sensitivity were found to mainly origin from the relatively lower cooling rate, higher fraction of low-angle grain boundaries (LAGBs) and smaller dendrite coalescence undercooling induced by the TC4 addition. Besides, the smaller temperature interval (10.63K) in the final solidification stage (0.90