Issues $\rightarrow$ Volume 26, Issue 4 (2025)

Advanced Layered Titanium-Based Materials 3D-Printed with Electron Beam and Cored Wire Approach

MARKOVSKY P.E.$^{1}$, KOVALCHUK D.V.$^{1,2}$, JANISZEWSKI J.$^{3}$, SAVVAKIN D.G.$^{1}$, FIKUS B.$^{3}$, SIENKIEWICZ J.$^{3}$, STASIUK O.O.$^{1}$, ORYSHYCH D.V.$^{1}$, NEVMERZHYTSKY V.I.$^{1,2}$, and TKACHUK V.P.$^{1,2}$

$^1$G.V. Kurdyumov Institute for Metal Physics of the N.A.S. of Ukraine, 36 Academician Vernadsky Blvd., UA-03142 Kyiv, Ukraine
$^2$JSC ‘NVO Chervona Hvylya’, 28 Dubrovitska Str., UA-04114 Kyiv, Ukraine
$^3$General Jarosław Dąbrowski Military University of Technology, 2 General Sylwester Kaliski Str., PL-00-908 Warsaw, Poland

Received / Final version: 30.06.2025 / 31.10.2025 Download PDF logo PDF

Abstract
Titanium-based layered materials, which combine hard layers of metal matrix composites (MMCs) with ductile alloy layers, show great promise for achieving enhanced mechanical and service performance. In this study, two-layer materials are investigated, consisting of a base substrate made of cast and wrought titanium alloy (T–6Al–4V plates), with top layers of MMCs 3D-printed on them. These MMC layers are also based on the Ti-6Al–4V alloy and reinforced with 40 vol.% TiC particles. A cored wire containing the MMC composition is used as feedstock in an advanced 3D-printing technique that employs a low-voltage profile electron beam as the heat source, enabling optimised coaxial wire feeding. The results show that, by varying the thicknesses of the individual layers, it is possible to create advanced materials, which exhibit a superior combination of strength, hardness, and ductility, i.e., properties, which are not achievable in single-layer cast or wrought titanium alloys or in standalone MMCs. To identify the features responsible for the enhanced properties, we examined the microstructure of the 3D-printed MMC layers and the interface with the base materials in detail. Ballistic tests are conducted on the layered MMC/alloy materials to evaluate their suitability for use in bullet-resistant applications. The effects of microstructure, layer thickness, and the combination of constituent materials on protective performance are analysed to optimise the balance of desirable properties. These materials are also compared with other types of 3D-printed layered and homogeneous titanium-based materials in terms of ballistic resistance. Their potential place among other armour materials is discussed.

Keywords: Ti-based materials, metal matrix composites, additive manufacturing, 3D printing with electron beam and wire, hard particles, microstructure, terminal ballistic testing.

DOI: https://doi.org/10.15407/ufm.26.04.***

Citation: P.E. Markovsky, D.V. Kovalchuk, J. Janiszewski, D.G. Savvakin, B. Fikus, J. Sienkiewicz, O.O. Stasiuk, D.V. Oryshych, V.I. Nevmerzhytsky, and V.P. Tkachuk, Advanced Layered Titanium-Based Materials 3D-Printed with Electron Beam and Cored Wire Approach, Progress in Physics of Metals, 26, No. 4: ***–*** (2025)

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