This paper reports the effect of laser power density on the evolving properties of laser metal deposited titanium alloy. A total of sixteen experiments were performed, and the microstructure, microhardness and surface roughness of the samples were studied using the optical microscope (OP), microhardness indenter and stylus surface analyzer, respectively. The microstructure changed from finer martensitic alpha grain to coarser Widmastätten alpha grain structure as the laser power density was increased. The results show that the higher the laser power density employed, the smoother the obtained surface. The microhardness initially increased as the laser power density was increased and then decreased as the power density was further increased. The result obtained in this study is important for the selection of proper laser power density for the desired microstructure, microhardness and surface finish of part made from Ti6Al4V.
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