Influence of Microstructure and Alloy Composition on the Machinability of α/β Titanium Alloys

Abstract

A comparative study was conducted for the machining of two α/β titanium alloys, namely Ti-6Al-4V (Ti64) and Ti-6Al-7Nb (Ti67), using wire electric discharge machining (WEDM). The influence of cutting speed and cutting mode on the machined surfaces in terms of surface roughness (Ra), recast layer (RL), and micro-hardness have been evaluated. Rough cut (RC) mode at a cutting speed of 50 µm/s resulted in thermal damage; Ra was equal to 5.68 ± 0.44 and 4.52 ± 0.35 µm for Ti64 and Ti67, respectively. Trim-cut mode using seven cuts (TRC-VII) at the same speed decreased the Ra to 1.02 ± 0.20 µm for Ti64 and 0.92 ± 0.10 µm for Ti67. At 100 µm/s, Ra reduced from 2.34 ± 0.28 µm to 0.88 ± 0.12 µm (Ti64), and from 1.42 ± 0.15 µm to 0.90 ± 0.08µm (Ti67) upon changing from TRC-III to TRC-VII. Furthermore, a thick recast layer of 30 ± 0.93 µm for Ti64 and 14 ± 0.68 µm for Ti67 was produced using the rough mode, while TRC-III and TRC-VII modes produced layers of 12 ± 1.31 µm and 5 ± 0.72 µm for Ti64 and Ti67, respectively. Moreover, rough cut and trim cut modes of WEDM played a significant role in promoting the surface hardness of Ti64 and Ti67. By employing the Response Surface Methodology, it was found that the machining mode followed by cutting speed and the interaction between them are the most influential parameters on surface roughness. Finally, mathematical models correlating machining parameters to surface roughness were successfully developed. The results strongly promote the trim-cut mode of WEDM as a promising machining route for two-phase titanium alloys.

Experimental Investigation on Bio-Machining of Nickel, Titanium and Nitinol (Shape Memory Alloys) Using Acidithiobacillus ferrooxidans Microorganisms

“…Controlling this size has a positive effect on cell adhesion and biocompatibility. The hot work of titanium is performed at a slow rate, which increases the production time and cost [3,10].…”

Experimental Investigation on Machinability of α/β Titanium Alloys with Different Microstructures

“…The alloys differ in the β-phase stabilizing element (V or Nb) and Ti67 has a finer microstructure than Ti64 [24]. In a recent study by Shehata et al [25], it was found that the variations in alloy composition and microstructure between Ti-6Al-4V and Ti-6Al-7Nb alloys dictated different behavior in their machinability when cut using wire electric discharge machining (WEDM). Ti64 alloy, with the coarser microstructure, developed a thicker recast layer and higher surface roughness (Ra) than Ti67.…”

“…Though some research was undertaken to compare the recently developed Ti67 alloy [26] to the commercial Ti64 alloy in terms of microstructure, mechanical properties [24], and biocompatibility [27], no work was performed to contrast their machinability using conventional machining processes (drilling, milling, etc.). Since these two alloys have some variations in their chemical compositions and exhibited different surfaces upon cutting using WEDM [25], they are also expected to show different machinability during the drilling process. In the current investigation, cast Ti64 and Ti67 alloy samples were prepared by the vacuum arc melting method and subjected to a series of heat treatments.…”