Complex closed-die forgings require numerous deformation steps and often multiple sets of tooling to transform simple mill product configurations into the final intended shapes. Methods to manufacture preforms, or intermediate shapes, for such components are of great interest for economic and process flow reasons. Laser deposited Ti-6Al-4V (Ti64) has been investigated as a potential input material for subsequent closed-die forging operations. An assessment was conducted on as-deposited Ti64 material to develop an understanding of the microstructural evolution that results from various thermo-mechanical processing methods. Controlled forging and annealing was shown to readily recrystallize the as-deposited microstructure, which consisted of coarse beta transformed structures. A full-scale, near-net airframe component preform was produced by laser forming and was single-step, closed-die forged in to a final airframe configuration. The results of the testing and assessment of the full-scale component showed that laser deposited titanium material was successful in producing the final component property requirements.
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