A novel solution treatment and aging for powder bed fusion–laser beam Ti–6Al–2Sn–4Zr–6Mo alloy: Microstructural and mechanical characterization

• A novel solution treatment and aging (STA) process for PBF-LB Ti-6Al-2Sn-4Zr-6Mo alloy achieves an ultrafine bilamellar microstructure with enhanced mechanical properties. • The optimized STA treatment improves hardness by 13% and ultimate tensile strength by 23% compared to conventional annealing. • Solution temperature and cooling media critically influence the α/β ratio and primary α-lamellae size, affecting microhardness and tensile performance. • Fractographic analysis reveals the fracture mechanisms associated with the optimized heat treatment, providing insights for aerospace and automotive applications.