Additive manufacturing of titanium aluminide high-temperature alloys by means of wire-based laser-assisted direct energy deposition

• Applicants: Professor Dr. Jens Freudenberger; Dr.-Ing. Johannes Günther
• Subject Area: Materials in Sintering Processes and Generative Manufacturing Processes ; Metallurgical, Thermal and Thermomechanical Treatment of Materials
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 553318092

The aim of this project is to provide a scientific and technological basis for the development of titanium aluminide build-up welds (laser-assisted-direct energy deposition). To date, no wire with the stoichiometry of a titanium aluminide, neither binary nor in an application-relevant composition, exists that would be suitable for build-up welding. We want to show that it is possible to cold work a composite wire of aluminum and titanium, as well as with small additions of niobium and chromium, and thereby to transfer it into a wire geometry suitable for laser and wire-based additive manufacturing. Furthermore, the phase composition of the wire will be adjusted by heat treatments, whereby the global chemical composition of the component has to be targeted in a controlled manner during processing and local deviations have to be prevented. We want to show that this wire can be successfully used for wire-based additive manufacturing. This would create a possibility to repair such components in the future. The additively manufactured semi-finished products will be characterized with respect to their microstructure and mechanical properties in order to evaluate their competitiveness compared to conventional manufacturing processes.

• DFG Programme: Research Grants