Experimental data on Ti-6Al-4V and Cu powder blends for additive manufacturing

Short Description This dataset contains 167 files from experiments on blending Ti-6Al-4V powder with pure Cu powder in three proportions (10, 15, and 20 wt.%). It includes light microscope and SEM images, raw experimental data (Excel), and EDS measurements (CSV/TXT). The data provide detailed insights into sample preparation, microstructural analysis, and processing parameters. Full Description This dataset contains 167 files related to the study of blending Ti-6Al-4V powder with pure Cu powder in three different proportions (10, 15, and 20 wt.%). The dataset includes: 51 light microscope and SEM images, 10 Excel sheets with raw experimental data, CSV and TXT files of all EDS measurements. Sample preparation and imagingFor SEM analysis, samples were eroded at half width, hot-embedded in bakelite (Epomet, Buehler, USA), mechanically ground with SiC abrasive paper, polished with a 9 µm suspension (Allegro DiaPro, Struers GmbH, Germany) for 5 min, and fine-polished for 20 min using a 0.02 µm cloth (OP-Chem, Struers, Germany) with Mastermet II suspension (Buehler, USA). Microstructural overview images for porosity analysis were captured with an optical microscope (Leica M205A, Wetzlar, Germany) using objectives 0.63, zoom factors 0.952 or 1.747, and eyepiece magnifications 6.0:1 or 11.0:1. Porosity analysis was performed using the Otsu method to determine optimal grayscale thresholds. Microstructure contrast was achieved by etching with Kroll’s reagent for 60 s at room temperature. Elemental analysisElement distributions were measured using EDS on a SEM (Vega II XLH, Tescan) at 15 kV, 1,000–3,000× magnification, and a working distance of ~24 mm. Chemical homogenization was analyzed with energy-dispersive X-ray spectroscopy (EDS) on a JXA-8200 system (JEOL, Japan). Processing parametersNine process parameters were systematically varied for all blends. Initial settings were derived from prior screening of Ti-6Al-4V (density 99.8 %). To extend the study, the volumetric energy density (EV) was varied in 20 % increments, and two additional parameter sets from the literature were included [https://doi.org/10.1002/maco.202011650, https://doi.org/10.1016/j.jmbbm.2020.104130]. Cubic samples (10 × 10 × 10 mm³) were produced with a stripe scanning strategy, 50 µm layer thickness, 50 µm laser spot, and 200 °C substrate heating. Materials and equipmentSpecimens were fabricated using an Aconity3D Mini system. The powders used were gas-atomized Ti-6Al-4V (LPW Technology Ltd.) and spherical, high-purity Cu powder (NMD – New Materials Development GmbH). Keywords Ti-6Al-4V; titanium alloys; copper; powder blending; additive manufacturing; laser powder bed fusion; microstructure; porosity analysis; scanning electron microscopy (SEM); energy dispersive spectroscopy (EDS); raw experimental data Author Contributions Conceptualization: A.L.S., M.L.A., A.T.; methodology: A.L.S., A.T.; data creation, printing and imaging: A.L.S.; Data analysis: A.L.S., M.L.A.; supervision: A.T.; funding acquisition: A.T. Funding This work is funded by the University of Bremen Research Alliance (UBRA) AI Center for Healthcare within the project ENABLE.