Ultrafine-grained (UFG) structure formation in Ti alloys, by severe plastic deformation (SPD) processing and enhancement of their mechanical properties, including fatigue properties, has been demonstrated in numerous studies in the past 20 years. The present overview analyzes the fatigue properties achieved to date in Ti alloys subjected to SPD. Such aspects are examined as the effect of a UFG structure on the fatigue behavior of commercially pure (CP) Ti, two-phase Ti alloys, using the popular Ti-6Al-4V alloy as an example, as well as on the kinetics and mechanisms of fatigue failure. The prospects and problems of the practical application of UFG Ti materials in medicine and aircraft engine construction are discussed.

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Grain reduction in a widely used Ti-6Al-4V alloy increases its endurance limit at room temperature. In this work, the behavior of the ultrafine-grained alloy under cyclic load at the temperature of 625 K is considered. Research was conducted to examine the fatigue life in a low-cycle area of the ultrafine-grained Ti-6Al-4V alloy produced by equal-channel angular pressing. Tensile and fatigue testing of the Ti-6Al-4V samples with coarse-grained (CG) and ultrafine-grained (UFG) structures were carried out at 293 and 625 K. The alloy demonstrated an enhanced strength and fatigue life at both temperatures. The representative features of the microstructural evolution and the fracture features in the UFG and CG alloys after fatigue tests are described in detail. The prospects for the use of the UFG Ti-6Al-4V alloy for engineering applications, such as in the production of critical gas-turbine engine parts, is discussed.

Research has demonstrated that the formation of a bulk ultrafine‐grained (UFG) structure in metals and alloys through severe plastic deformation (SPD) enables increasing of their strength properties and decreasing of the temperature range of superplasticity. Designers and process engineers generally show a great interest in such materials because the development of mechanical engineering industries places ever‐increasing demands on the performance properties of commercial alloys, especially for parts operating under extreme conditions. One of the approaches for a comprehensive enhancement of the performance characteristics of structural materials is a combination of a UFG structure in the bulk of a material, providing an increase in strength, and an additional surface modification providing resistance to erosion and corrosion damage. As a result, a set of material service properties can be enhanced, which is difficult to achieve through only metal nanostructuring or only surface modification. This approach has been demonstrated through an example of UFG titanium alloys produced by SPD, including those with nanostructured multilayer TiVN coatings of different “architectures.” Accordingly, herein, the trends, problems, and prospects of surface modification for the innovative application of structural UFG titanium alloys in advanced mechanical engineering are examined.

Wire arc additive manufacturing (AM) is able to replace the traditional manufacturing processes of Ti alloys. At the same time, the common drawback of Ti workpieces produced by AM via wire deposition welding is the formation of a coarse-grained dendritic structure, its strong anisotropy and, consequently, lower strength as compared to a monolithic alloy. In this work, a new method is proposed for the enhancement of the strength properties of the Ti-6Al-4V alloy synthesized by AM via wire deposition welding, which involves the use of a wire with an initial ultrafine-grained (UFG) structure. The UFG wire is characterized by a large number of defects of the crystalline lattice and grain boundaries, which will enable increasing the number of “crystallization centers” of the α-phase, leading to its refinement. The macro- and microstructure, phase composition and microhardness of the Ti-6Al-4V alloy samples were investigated. The microhardness of the alloy produced by layer-by-layer deposition welding using a UFG wire was shown to be on average 20% higher than that of the samples produced by a deposition welding using a conventional wire. The nature of this phenomenon is discussed, as well as the prospects of increasing the mechanical characteristics of Ti alloys produced by additive manufacturing.