Journal of Welding Science

The Ti-6242 alloy is of particular significance in additive manufacturing due to its high thermal resistance. However, components fabricated from this alloy using the electron beam powder bed fusion (EB-PBF) process often exhibit poor surface quality, primarily resulting from the layer-by-layer fabrication nature and and the presence of partially melted powder particles. In this study, laser polishing was employed to enhance the surface characteristics of EB-PBF fabricated Ti-6242 specimens using three laser powers (195, 260, and 325 W) and two scanning speeds (4.5 and 3 mm/s). The effects of these parameters on surface roughness, microstructure, and mechanical properties were evaluated through surface profilometry, metallography, hardness, and wear tests. The results indicated that the average surface roughness decreased by up to 93%, from 9.36 µm to 0.61 µm. Moreover, the initial α and β phases transformed into a fine, martensitic α′ phase within the polished layer, leading to a 33% increase in hardness—from 380 to 506 HV—and a significant improvement in wear resistance. Consequently, optimal adjustment of laser polishing parameters can simultaneously reduce surface roughness and enhance the mechanical performance of Ti-6242 components.