Systems and methods for wire deposited additive manufacturing using titanium

A method of additive manufacturing, comprising:

• mixing a plurality of powdered metals comprising titanium, iron, vanadium, and aluminum to produce a powder blend;
• cold isostatic pressing and sintering the powder blend to form a billet;
• performing a wire forming operation on the billet to produce a worked wire, wherein the wire forming operation includes extruding the billet through a die;
• heat treating the worked wire to produce a heat treated wire;
• coiling the heat treated wire onto a feed spool;
• loading a first structural element into an additive manufacturing machine, the first structural element having a first side, a second side, a first face, and a second face;
• loading the feed spool into the additive manufacturing machine;
• printing a second structural element of the heat treated wire from the feed spool, the second structural element being integral to the first structural element to form a part, wherein the second structural element is deposited over including depositing a first flange portion proximate the first side and extending perpendicular from the first face in a first direction;
• and
• heat treating the part to generate a functionally graded monolithic structure.