LAUSR

Herein, an innovative powder‐cored wire arc additive manufacturing (PC‐WAAM) process is proposed to fabricate γ‐TiAl thin‐walled intermetallic alloy. The metallography, phase composition, and mechanical properties at different thin‐wall locations are characterized. The results show that the alternatively distributed layer‐like microstructure composed of α2 (Ti3Al) and γ (TiAl) phases is obtained along the building direction. The content of α2 phase exhibits the tendency of decreasing from the bottom to top region. This unique microstructure characteristic is closely related to the typical thermal cycling history during deposition. Moreover, the tensile strength and microhardness of the top region are lower than the middle and bottom region. In general, the current PC‐WAAM technique shows promising capability of fabricating γ‐TiAl intermetallic alloy with low cost. This work becomes a valuable reference for understanding the evolution mechanism of microstructure and paves the way for the flexible and customized additive manufacturing of γ‐TiAl alloy.