Additive Manufacturing of Ti-Based Intermetallic Alloys: A Review and Conceptualization of a Next-Generation Machine

Dzogbewu, Thywill Cephas; Preez, Willie du

doi:10.3390/ma14154317

Cited by 36 publications

(17 citation statements)

References 66 publications

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“…Despite the well-celebrated advantages offered by the LPBF process, it is well documented that the surface quality of LPBF products is one of its main drawbacks, limiting the technology from widespread industrial applications [62]. Currently, the LPBF process is mainly used to produce highvalue products for biomedical and engineering applications in the aerospace and automobile industries [16]. These industries require a specific surface quality for a specific application.…”

Section: Surface Quality Of the Ti10mo Alloy Matrix Layersmentioning

confidence: 99%

“…Despite these confirmations of low elasticity, non-toxicity, preferential biomechanical and biochemical properties of the Ti-Mo alloy, the processing of the Ti10Mo alloy via the conventional methods (casting, forging, sheet forming, extrusion, etc.) was very difficult [16,17]. This is because Mo is a refractory metal with a high melting point [18].…”

Section: Introductionmentioning

confidence: 99%

“…This is because Mo is a refractory metal with a high melting point [18]. The addition of Mo to Ti increases the melting point of the alloy making the processing of the material very difficult [16,19]. As a result, the conventional methods of manufacturing could not be used to produce the alloy without defects (porosity, shrinkage, inhomogeneous microstructures) [17].…”

Section: Introductionmentioning

confidence: 99%

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In situ alloying of Ti10Mo fused tracks and layers via laser powder bed fusion

Dzogbewu

Preez

2022

Manufacturing Rev.

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Optimum process parameters for manufacturing a Ti10Mo alloy for biomedical applications via the laser powder bed fusion (LPBF) process were determined. Fused tracks were produced over a wide range of laser powers and scanning speeds, and layers were fused at varied hatch distances. The samples were analysed for continuity of the fused tracks, melting and distribution of the Mo powder particles in the Ti10Mo alloy layers, surface roughness, homogeneity of Mo in the alloy matrix and microhardness. The analysis revealed that the Mo powder particles melted completely in the alloy matrix with only pockets of Mo concentrations, mostly at the peripheries of the fused tracks due to the pushing effect. Complete melting of Mo in the Ti10Mo alloy matrix was due to the small size (1 μm) of the Mo powder particles used in the current experiment. The addition of Mo enhanced the wetting of the powder bed and prevented a pronounced balling effect. From this study, the parameter sets 150 W, 0.5 m/s and 200 W, 1.0 m/s both at a hatch distance of 80 μm, were obtained as the optimum process parameters. However, the Mo concentrations at the peripheries of the molten pool indicated that further research was required before a ‘completely’ homogenous sample could be manufactured via the LPBF process using elemental powder blends.

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Section: Surface Quality Of the Ti10mo Alloy Matrix Layersmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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In situ alloying of Ti10Mo fused tracks and layers via laser powder bed fusion

Dzogbewu

Preez

2022

Manufacturing Rev.

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“…With the advantages of low density, high melting point, and high specific strength, TiAl alloy has great potential in the field of aerospace. Numerous scholars have carried out studies on the processing methods and mechanical properties of TiAl-based alloys [ 1 , 2 , 3 , 4 ]. Cheng et al [ 5 ] studied the high-temperature deformation properties of a TiAl-based alloy and found that super-plasticity occurs—that is, when the temperature reaches 1000 ℃, the deformation mechanism of this alloy converted from the original dislocation slip and twinning to a grain boundary sliding mode.…”

Section: Introductionmentioning

confidence: 99%

The Relationship between Microstructure and Fracture Behavior of TiAl/Ti2AlNb SPDB Joint with High Temperature Titanium Alloy Interlayers

et al. 2022

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In this paper, spark plasma diffusion bonding technology was employed to join TiAl and Ti2AlNb with high temperature titanium alloy interlayer at 950 °C/10kN/60 min, then following furnace cooling at cooling rate up to 100 °C/min. After welding, the joint was aging heat-treated at 800 °C for 24 h. The microstructure and the elements diffusion of the TiAl/Ti2AlNb joint was analyzed by field emission scanning electron microscopy (FESEM) with EDS. Moreover, the tensile properties of the joint were tested at room temperature, 650 °C, and 750 °C. The results show that the spark plasma diffusion bonding formed a high quality TiAl/Ti2AlNb joint without microcracks or microvoids, while also effectively protecting the base metal. Significant differences in the microstructure of the joint appeared from TiAl side to Ti2AlNb side: TiAl BM (Base Metal) → DP(Duplex) and NG (Near-Gamma) → α2-phase matrix with needle-like α-phase → bulk α2-phase → needle-like α-phase → metastable β-phase → Ti2AlNb BM. After heat treatment at 800 °C for 24 h, the microstructure of the TiAl side and the interlayer region did not change, but the density and size of the needle-like α-phase in region 3 increased slightly. The microstructure of Ti2AlNb near the weld changed obviously, and a large number of fine O phases are precipitated from the metastable β phase matrix after heat treatment. Except for the Ti2AlN near-interface region, the effect of heat treatment on the microstructure of the joint is not significant. The microhardness of the joint is in the shape of a mountain peak. The maximum microhardness at the interface is above 500 HV, and it is significantly reduced to 400 HV after heat treatment. The fracture of the joint occurred at the interface at room temperature, 650 °C, and 750 °C. with the tensile strength 450 MPa, 540 MPa, and 471 Mpa, respectively, and mainly showing brittle fracture.

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“…In terms of Nickel-Titanium alloy, both superelasticity and shape memory effect are used for stents to decrease their volume during placement with subsequent extension under temperature influence and to impart a constant load on the walls of the vessel respectively. Furthermore, for intermetallic alloys such as NiTi [ 22 , 23 , 24 , 25 ], TiAl [ 26 , 27 ], NiAl [ 28 ], etc. application of LPBF technology can remarkably reduce the cost of the parts with complex geometries due to the poor machining of the material associated with high ductility accompanied by a strongly pronounced strain hardening effect [ 29 ].…”

Section: Introductionmentioning

confidence: 99%

The Study on Resolution Factors of LPBF Technology for Manufacturing Superelastic NiTi Endodontic Files

et al. 2022

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Laser Powder Bed Fusion (LPBF) technology is a new trend in manufacturing complex geometric structures from metals. This technology allows producing topologically optimized parts for aerospace, medical and industrial sectors where a high performance-to-weight ratio is required. Commonly the feature size for such applications is higher than 300–400 microns. However, for several possible applications of LPBF technology, for example, microfluidic devices, stents for coronary vessels, porous filters, dentistry, etc., a significant increase in the resolution is required. This work is aimed to study the resolution factors of LPBF technology for the manufacturing of superelastic instruments for endodontic treatment, namely Self-Adjusting Files (SAF). Samples of thin walls with different incline angles and SAF samples were manufactured from Nickel-Titanium pre-alloyed powder with a 15–45 μm fraction. The printing procedure was done using an LPBF set-up equipped with a conventional ytterbium fiber laser with a nominal laser spot diameter of 55 microns. The results reveal physical, apparatus, and software factors limiting the resolution of the LPBF technology. Additionally, XRD and DSC tests were done to study the effect of single track based scanning mode manufacturing on the phase composition and phase transformation temperatures. Found combination of optimal process parameters including laser power of 100 W, scanning speed of 850 mm/s, and layer thickness of 20 μm was suitable for manufacturing SAF files with the required resolution. The results will be helpful for the production of NiTi micro objects based on periodic structures both by the LPBF and μLPBF methods.

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Additive Manufacturing of Ti-Based Intermetallic Alloys: A Review and Conceptualization of a Next-Generation Machine

Cited by 36 publications

References 66 publications

In situ alloying of Ti10Mo fused tracks and layers via laser powder bed fusion

In situ alloying of Ti10Mo fused tracks and layers via laser powder bed fusion

The Relationship between Microstructure and Fracture Behavior of TiAl/Ti2AlNb SPDB Joint with High Temperature Titanium Alloy Interlayers

The Study on Resolution Factors of LPBF Technology for Manufacturing Superelastic NiTi Endodontic Files

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