Solution treatment of Ti-6Al-4V alloy produced by consolidating blended powder mixture using a powder compact extrusion route

Titanium alloys are very sensitive to thermal history and different microstructures are obtained depending on their chemistry, processing route and post-processing heat treatment. The objective of this paper is to characterise solution-treated Ti-6Al-4V alloy rods from microstructural investigations using optical and transmission electron microscopy (TEM) in addition to measurements of chemical composition and levels of impurity oxygen. From the results, it is clear that the compositions and oxygen concentration of the different rods, which varied between 0.34-0.36 wt%, was consistent from one extrusion to another. TEM analysis of the as-extruded material with a fine lamellar microstructure indicates that the severe deformation and attendant dynamic recrystallization during and after hot extrusion did not give rise to any undesirable features that can degrade the ductility. Solution treatment above the beta transus and subsequent ageing causes grain growth with grains containing a metastable martensitic structure (only alpha' phase was present), some retained beta and a limited formation of acicular secondary alpha. The alpha + beta quenched and aged treatment gives a lamellar type morphology, but at the alpha interfaces there is retained beta with some secondary alpha and potentially some alpha' phase. In terms of mechanical behaviour, the data from v-notch Charpy impact tests and non-standard micro-tensile testing suggests that both water quenched and aged microstructures give a higher yield strength (similar to 1022-1033 MPa) and micro-hardness (388 HV), while the fracture-related properties such as estimated plastic strain and impact toughness were between 5-6% and 13.7 J respectively. Overall, the level of mechanical properties reported here is better than that for typical values reported in the literature for as-cast material after similar solution treatments.