Phase Evolution and Mechanical Behavior of a Novel Ti–6.3Cu–2.2Fe−2.1Al Alloy Processed by Wire-Arc Directed Energy Deposition

Lacking Ti-alloy wires tailored for wire-arc directed energy deposition (waDED) restricts AM-component implementation. Ti–Cu alloys show potential but require additional elements to enhance performance. In this work, waDED-processed Ti–6.3Cu–2.2Fe−2.1Al is characterized. Addition of Cu to Ti achieves a columnar-to-equiaxed transition. The microstructure consists of fine Ti2Cu precipitates, β matrix, and α plates, with varying morphologies along the deposit’s height due to differing thermal histories. The as-built sample exhibits a σ Y of 1039 MPa but low ductility.