Ti-6Al-4V is difficult to machine via milling or turning [1–3]; therefore, near-net-shape manufacturing offers significant advantages as it can reduce the amount of material to be subtracted down to the final dimension [4,5]. Additive manufacturing can be used to accomplish near-net-shapes [6,7], but its low deposition rate makes it less attractive for industry. In the present study, we investigated how a rectangular laser spot with a top hat intensity distribution can be used to increase the deposition rate of Ti-6Al-4V for powder-based laser direct energy deposition. Deposited single tracks, layers, and solid bodies were built to study the effect of processing parameters on the microstructure evolution. Post thermomechanical treatment was carried out at different temperatures and strain rates using a deformation dilatometer. Track geometry, bonding defects, and microstructure were analyzed. The high deposition rate was increased up to 5 kg/h, while the process remained stable. Global shielding from the surrounding air is mandatory to prevent oxidation since the deposited volume heats up quickly.


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