The implementation of additive manufacturing techniques in the production of mission critical structural components is challenged by its low throughput and limited build envelope. In recent years, hybrid production methods are emerging to bridge between the build volume and high throughput of conventional production methods and the design freedom enabled by additive manufacturing. The repeatability of material properties and the quality of the interface between the additive manufactured and wrought material are crucial for the adoption of hybrid manufacturing techniques by the industry. Here, the tensile behavior and fracture toughness of a hybrid Ti-6Al-4V alloy are examined in detail. Ti-6Al-4V pre-forms were built onto a wrought Ti-6Al-4V start-plate and extracted via milling. Compact tension and uniaxial tension specimens extracted from the hybrid pre-forms demonstrated good fracture and properties with no preference for crack growth in neither the AM nor wrought materials. Microstructural characterization revealed a 40 mm transition layer into the wrought material which ends abruptly with no evidence of a gradually decaying heat-affected zone. The hybrid manufacturing approach studied here expands the current limitations of large-scale critical components with fine features and allow such structures to be produced with a higher throughput.

增材制造技术在任务关键型结构部件的生产中的实施受到其低产量和有限的建造空间的挑战。近年来，出现了混合生产方法，以在传统生产方法的生产量和高产量与增材制造带来的设计自由之间架起桥梁。材料特性的可重复性以及添加剂制造和锻造材料之间的界面质量对于行业采用混合制造技术至关重要。在此，详细研究了混合Ti-6Al-4V合金的拉伸行为和断裂韧性。将Ti-6Al-4V预成型件构建在锻造的Ti-6Al-4V起始板上，然后通过铣削提取。从混合预成型件中提取的致密张力和单轴张力样品显示出良好的断裂和性能，在AM和锻造材料中均不倾向于裂纹扩展。显微组织特征表明，在锻造材料中有一个40 mm的过渡层，该过渡层突然终止，没有证据表明热影响区逐渐衰减。本文研究的混合制造方法扩大了具有关键特征的大型关键部件的当前限制，并允许以更高的生产率生产此类结构。显微组织特征表明，在锻造材料中有一个40 mm的过渡层，该过渡层突然终止，没有证据表明热影响区逐渐衰减。本文研究的混合制造方法扩大了具有关键特征的大型关键部件的当前限制，并允许以更高的生产率生产此类结构。显微组织特征表明，在锻造材料中有一个40 mm的过渡层，该过渡层突然终止，没有证据表明热影响区逐渐衰减。本文研究的混合制造方法扩大了具有关键特征的大型关键部件的当前限制，并允许以更高的生产率生产此类结构。