The present work focused on the strengthening of Ti-6Al-4V alloy, which is used for a wide range of aerospace and biomedical structural applications. A new tailored heterogeneous microstructural design with bimodal grain size distribution and specific topological distribution of fine and coarse grains, called "harmonic structure", and suitable powder metallurgy (PM) based processing approach has been developed to achieve the same. In the present work, harmonic structured Ti-6Al-4V alloy was successfully prepared via a PM approach consisting of controlled severe plastic deformation of the pre-alloyed powders followed by spark plasma sintering. The microstructural evolution at each stage of processing and mechanical properties of the resulting material was investigated. The harmonic structured Ti-6Al-4V alloy exhibited superior tensile properties as compared to their coarse/fine-grained counterparts. An attempt has been made to understand the correlation between the unique microstructural design and improved mechanical properties in the harmonic structured Ti-6Al-4V alloys.
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