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Simulating the additive manufacturing process of Ti-6Al-4V is very complex due to the microstructural changes and allotropic transformation occurring during its thermomechanical processing. The α-phase with a hexagonal close pack structure is present in three different forms—Widmanstatten, grain boundary and Martensite. A metallurgical model that computes the formation and dissolution of each of these phases was used here. Furthermore, a physically based flow-stress model coupled with the metallurgical model was applied in the simulation of an additive manufacturing case using the directed energy-deposition method. The result from the metallurgical model explicitly affects the mechanical properties in the flow-stress model. Validation of the thermal and mechanical model was performed by comparing the simulation results with measurements available in the literature, which showed good agreement.

The usages of nonferrous alloys in industries are rapidly increasing due to their excellent properties such as strength, ductility, malleability, toughness and corrosion resistance. Brass is one of the nonferrous alloy which is used in many applications such as automobile, aerospace medical and electrical fields. In this experimental investigation, α-β brass was formulated by stir casting technique and the material characterization is examined with the Scanning Electron Microscope and Energy Dispersive Analysis of X-rays. The process parameters of Abrasive Water Jet Machining such as water pressure, traverse speed and mass flow rate are considered to study the machining of α-β brass using the Taguchi methodology. The effect of these process parameters on the responses such as Surface Roughness and Material Removal Rate were studied by varying the control process parameters. The optimum permutation of the process parameters were identified for maximum MRR and minimum SR. The most prominent parameters were found out by Analysis of Variance.

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