Laser deposition of titanium alloys is under consideration for aerospace applications, and
offers significant increases in efficiency and flexibility compared to conventional manufacturing
methods. However, its ultimate success will depend on the ability to predict and control the
microstructure and resulting mechanical properties of the deposit. In this study, both 2-D
continuum finite element modeling and 3-D cellular automaton finite element modeling of a thinwall geometry are used to investigate the effects of deposition process variables on microstructure
in laser deposited Ti-6Al-4V. Numerical results for cooling rate and thermal gradient obtained from
the 2-D models are used to provide insight into grain size and morphology, while the 3-D cellular
automaton models are used to provide direct predictions of deposited microstructure. The
numerical model predictions are subsequently compared with observed microstructures in LENSTM
deposited Ti-6Al-4V.This work was supported by the Joint AFRL/DAGSI Research Program, project number
ML-WSU-01-11, as well as by a grant from Wright State University and the Ohio Board of
Regents.Mechanical Engineerin
