The results from this study, on a few commercial and model metastable beta titanium alloys, indicate that the growth restriction factor (GRF) model fails to interpret the grain growth behavior in the additively manufactured alloys. In lieu of this, an approach based on the classical nucleation theory of solidification incorporating the freezing range has been proposed for the first time to rationalize the experimental observations. Beta titanium alloys with a larger solidification range (liquidus minus solidus temperature) exhibited a more equiaxed grain morphology, while those with smaller solidification ranges exhibited columnar grains. Subsequently, the printability of two candidate beta titanium alloys containing eutectoid elements (Fe) that are prone to beta fleck in conventional casting, i.e., Ti-1Al-8V-5Fe (wt%) or Ti-185, and Ti-10V-2Fe-3Al (wt%) or Ti-10-2-3, is further investigated via two different AM processing routes. These alloys are used for high-strength applications in the aerospace industry,

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The penchant towards development of high performance materials for light weighting engineering systems through various thermomechanical processing routes has been soaring vigorously. Friction stir processing (FSP) - a relatively new thermomechanical processing route had shown an excellent promise towards microstructural modification in many Al and Mg alloy systems. Nevertheless, the expansion of this process to high temperature materials like titanium alloys and steels is restricted by the limited availability of tool materials. Despite it challenges, the current thesis sets a tone for the usage of FSP to tailor the mechanical properties in titanium alloys and steels. FSP was carried out on three near beta titanium alloys, namely Ti6246, Ti185 and Tiβc with increasing β stability index, using various tool rotation rates and at a constant tool traverse speed. Microstructure and mechanical property relationship was studied using experimental techniques such as SEM, TEM, mini tensile testing and synchrotron x-ray diffraction. Two step aging on Ti6246 had resulted in an UTS of 2.2GPa and a specific strength around 500 MPa m3/mg, which is about 40% greater than any commercially available metallic material. Similarly, FSP on an ultra-high strength steel―Eglin steel had resulted in a strength greater than 2GPa with a ductility close to 10% at around 4mm from the top surface of stir zone (SZ). Experimental techniques such as microhardness, mini-tensile testing and SEM were used to correlate the microstructure and properties observed inside SZ and HAZ's of the processed region. A 3D temperature modeling was used to predict the peak temperature and cooling rates during FSP. The exceptional strength ductility combinations inside the SZ is believed to be because of mixed microstructure comprised of various volume fractions of phases such as martensite, bainite and retained austenite.