Additive Manufacturing (AM) has revolutionized production processes, offering unparalleled flexibility and efficiency. Titanium alloys, renowned for their high strength-to-weight ratio and corrosion resistance, are particularly significant in Aerospace and Oil & Gas applications. However, their high reactivity with oxygen and nitrogen at elevated temperatures poses challenges in processing, including the risk of contamination and the formation of undesirable phases. While Titanium alloys have been extensively applied in AM processes like Laser Metal Deposition (LMD), the emergence of 3D Extreme High-Speed Laser Metal Deposition (3D-EHLA) presents a new frontier.

This study, conducted using the Ponticon's pE3D system, delves into the behavior of Titanium alloys within the 3D-EHLA process, aiming to investigate the tailored microstructure of components. The application of specialized nozzles from Nidec, designed to deliver exceptionally high shielding gas flow rates of up to 100 L/min, addresses the challenge of minimizing contamination during deposition of Titanium alloys. Despite the proven effectiveness of such nozzles in standard LMD processes, where they have proved to be a viable alternative to working in inert chamber environments, their performance in the extreme high-speed requirements of 3D-EHLA remains unexplored territory.

Through comparative analyses between specialized Nidec nozzles and standard nozzles in the 3D-EHLA process, microstructural features including grain size, phase distribution, and the presence of contaminants and defects will be addressed.

In conclusion, this study contributes to advancing the understanding of Titanium alloys behavior in the 3D-EHLA process and provides insights into optimizing microstructural control and minimizing contamination. By addressing these challenges, the quality and reliability of additively manufactured components, particularly in critical industries like Aerospace and Oil & Gas, can be significantly enhanced.