Direct Laser Fabrication (DLF) has been used to manufacture near net shape components of Ti-6Al-4V and the effects of laser processing conditions on the microstructure have been assessed. Parts with various geometries, including a certain degree of overhangs, have been successfully built using DLF. Good geometry control and surface finish have been achieved. It has been found that laser processing conditions have significant effects on the microstructure of Ti-6Al-4V alloy. Parts with various porosity and fully dense components can be tailor made under suitable processing conditions.

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