A comparative study of laser direct metal deposition characteristics using gas and plasma-atomized Ti-6Al-4V powders

► An advanced volumetric porosity assessment is employed to powders and deposition. ► PREP powder shows potential benefits as deposition material in laser deposition. ► Micro hardness of laser deposited Ti-6Al-4V is related to lamellar α + β phase spacing. ► Nucleation plays a key role at higher mass flow during microstructure formation.