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The ability to create complex geometries with tailored material propertieshas brought interest in using additive manufacturing (AM) techniques in variousindustrial applications. However, the complex relationship between AM processparameters, microstructure, and resultant properties of metals needs to befully understood for the widespread use of metal AM. In this study, selectivelaser melting is used to print Ti-6Al-4V. In-situ tensile tests with concurrentdetailed microstructural analysis using electron backscatter diffraction,electron channeling contrast imaging, and digital image correlation areperformed to understand the damage mechanism and its relation to themicrostructure. Our results show that the as-printed part develops ahierarchical microstructures, consisting of primary, secondary, and tertiary{\alpha}^' martensite. This hierarchical structure is formed as a result ofcyclic heat treatment during the course of selective laser melting. Upondeformation, strain localization within primary {\alpha}^' martensite resultsin microscopic ductile micro-void formation and coalescence, as well asmacroscopic brittle fracture. In addition to localization inside primary{\alpha}^', surface steps at the boundaries of these high aspect ratio grainsare formed which reveal the contribution of interfacial plasticity to theoverall deformation of the material.

Plasticity and damage mechanisms in Ti-6Al-4V printed with selective laser melting