creator Cao, Jun advisor Nash, Philip Electron Beam Additive Manufacturing (EBAM), used to fabricate net or nearnet- shaped components based on a sliced CAD model, offers a potential alternative solution for the processing of titanium components, especially for large parts. However, the components fabricated using EBAM exhibit significant difficulties in quality control and quality assurance due to lack of knowledge of thermo-mechanical-metallurgical relationship. In this work, the thermo-mechanical behavior of wire-feed EBAM for largescale Ti-6Al-4V build plates has been investigated computationally and experimentally, with special attention to the distortion and residual stress, as well as the microstructural evolution. A 3D transient fully coupled thermo-mechanical finite element (FE) model was built, calibrated, and rigorously validated. To ensure the accuracy of the model, the bulk residual strain distribution was measured using neutron diffraction (ND), and the numerically simulated thermal profiles were physically simulated using a Gleeble® 3500, in addition to the conventional model validation methods. Good agreement was found between the simulation results and experimental measurements. A series of simulations were performed to determine the optimum process conditions. The simulation results indicated that preheating, increasing deposition power and scan rate, and decreasing interval cooling time effectively mitigates the distortion and residual stress. For EBAM Ti-6Al-4V build plates, increasing the energy input and reducing the heat loss renders smaller temperature difference and thermal expansion mismatch, consequently, leading to a lower level of distortion and residual stress. The deposited cladding was characterized by large columnar grains growing across layers, a bottom region with repeated macroscopic bands and a top region without these bands. The band structure exhibits mostly colony α. A fine basket-weave structure is observed above the band structure, and a coarse basket-weave structure is observed below the band structure. The simulated thermal profiles were used to understand the observed microstructure. It was found that the microstructure variation in the cladding of EBAM Ti-6Al-4V build plates is strongly dependent on the peak temperature within the (α+β) phase region, and heating rate and cooling rate have insignificant effects on it. The non-equilibrium solid-solid phase transformation of Ti-6Al-4V under continuous heating/cooling were experimentally investigated. The kinetics of phase transformation was quantitively studied and modeled using a non-isothermal JMAK (Johnson-Mehl-Avrami-Kolmorgorov) model, with the activation energy QA=123.9 kJ/mole, JMAK exponent n=1.8, and the calculated ln (k0) varied between 9.15 to 10.6 for different heating rate. Submitted by Erma Thomas (thomase@iit.edu) on 2018-03-19T21:03:46Z No. of bitstreams: 1 etdadmin_upload_525186.zip: 12339249 bytes, checksum: 5c0a43307b914877ee03f24fe77a6e5e (MD5) Made available in DSpace on 2018-03-19T21:03:46Z (GMT). No. of bitstreams: 1 etdadmin_upload_525186.zip: 12339249 bytes, checksum: 5c0a43307b914877ee03f24fe77a6e5e (MD5) Previous issue date: 2017-07 Ph.D. in Materials Science and Engineering, July 2017 2017 2017-07 http://hdl.handle.net/10560/4225 en Band structure Electron beam additive manufacture Neutron diffraction Phase transformation kinetics Residual stress and distortion Thermo-mechanical modeling Dissertation born digital application/pdf In Copyright http://rightsstatements.org/page/InC/1.0/ Restricted Access MMAE / Mechanical, Materials, and Aerospace Engineering Illinois Institute of Technology Affiliated department