Raji, SATlotleng, MSkhosane, Besabakhe SKanyane, LRPopoola, APIPityana, Sisa L2026-01-092026-01-0920251438-16561527-2648https://doi.org/10.1002/adem.202500737http://hdl.handle.net/10204/14572Generally, manufacturing valuable parts from General Electric's titanium aluminide (Ti-48Al-2Cr-2Nb; Ti4822) is extremely difficult. The difficulty is due to the alloy's poor room temperature castable and machining properties. To achieve functional parts from Ti4822 via cast and selective laser melting, built parts are hot isostatically pressed. Unfortunately, direct energy deposited Ti4822 parts are yet to be reported in open literature and hence this article wherein a 100 mm long pipe is laser metal deposited and investigated for use as a heat exchanger. Before printing, the theoretical model is used to predict geometric defects (tapering) and heat distribution. The results conclude tapering at around 30 mm and rapid increase in heat inputs (HIs). The microstructural analyses corroborated this observation, particularly the fracture analyses which indicated internal cracking, impurities and pores at moderate HI, and isotropic microstructure with elongation formed dimple grains at high HI position. Fracture is said to be transgranular, cleavage-like, and ductile-brittle overall. Nanoindentation results conclude that the pipe would withstand high stress due to high toughness. Pipe inner surface roughness is 5.190 μm, indicating acceptable pressure drops and therefore usable as a heat exchanger.FulltextenGeneral Electric's titanium aluminideLaser metal depositsEngineering materialsArticle