AccScience Publishing / MSAM / Online First / DOI: 10.36922/MSAM026210047
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ORIGINAL RESEARCH ARTICLE

Microstructural gradients and associated mechanical and fatigue behavior in DED Ti-6Al-4V across the build height

Andrea Školáková1 Jan Pinc1* Hana Lesáková2 Ondřej Kovářík3 Karel Tesař3 Orsolya Molnárová1 Michal Jambor4 Miroslav Lebeda1 Pavel Hutař4 Dalibor Vojtěch2
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1 Department of Functional Materials, FZU - Institute of Physics of the Czech Academy of Sciences, Prague, Czech Republic
2 Department of Metals and Corrosion Engineering, Faculty of Chemical Technology, University of Chemistry and Technology Prague, Prague, Czech Republic
3 Department of Materials, Faculty of Nuclear Sciences and Physical Engineering, Czech Technical University in Prague, Prague, Czech Republic
4 Department of Mechanical Properties, Institute of Physics of Materials of the Czech Academy of Sciences, Brno, Czech Republic
Received: 22 May 2026 | Revised: 24 June 2026 | Accepted: 1 July 2026 | Published online: 24 July 2026
© 2026 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
Abstract

Directed energy deposition enables efficient fabrication of complex Ti-6Al-4V components, yet process-induced microstructural gradients and porosity across the build height remain poorly understood with respect to their effects on mechanical and fatigue performance. In this study, we investigate the relationships between directed energy deposition process parameters, the resulting microstructure, and anisotropic mechanical behavior. The study expands the current understanding of directed energy deposition-processed Ti-6Al-4V by providing a detailed analysis of microstructural evolution in both build directions and presenting new insights into fatigue properties. The microstructural and mechanical characteristics of the alloy are systematically described with an emphasis on their mutual relationship. The material exhibited a predominantly α’ martensitic microstructure, with no significant variation in phase fraction as a function of distance from the build platform, consistent with the measured hardness. Electron backscatter diffraction analysis did not reveal a pronounced crystallographic texture, whereas transmission electron microscopy observations identified deformation twins within the α’ phase. Porosity was mainly oriented perpendicular to the build direction. The combination of a martensitic microstructure and the presence of pores resulted in low ductility. Under cyclic loading, pores acted as crack initiation sites, while their planar orientation limited their effect on crack propagation, indicating that the mechanical response was governed primarily by the martensitic microstructure rather than pore-assisted crack growth. Overall, the results highlight the critical role of microstructure and inherent defects in controlling the mechanical behavior of additively manufactured components and provide a basis for process optimization and post-processing strategies such as heat treatment or hot isostatic pressing.

Graphical abstract
Keywords
Directed energy deposition
Ti-6Al-4V alloy
Martensitic microstructure
Fatigue behavior
Additive manufacturing defects
Funding
This study was supported by the project “Mechanical Engineering of Biological and Bio-inspired Systems,” funded under project No. CZ.02.01.01/00/22_008/0004634 within the Programme Johannes Amos Commenius, Call: Excellent Research. Additional support was provided by the CzechNanoLab project LM2023051, funded by the Ministry of Education, Youth and Sports of the Czech Republic, which is gratefully acknowledged for enabling measurements and sample fabrication at the LNSM Research Infrastructure.
Conflict of interest
The authors declare they have no competing interests.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing