Investigation of the benefits of plasma deposition for the additive layer manufacture of Ti-6Al-4V

► Plasma welding and wire feeding have been successfully combined for ALM purposes. ► A working envelope that ensures deposition feasibility has been defined. ► Microstructure consists of coarse Widmanstätten in former β grains. ► A repetitive microstructural pattern was observed. ► A geometric model for three responses has been developed.