Machining of GTAW additively manufactured Ti-6Al-4V structures

Hoye, Nicholas P; Cuiuri, Dominic; Rashid, Rizwan Abdul Rahman; Palanisamy, Suresh

doi:10.1007/s00170-018-2494-8

Cited by 14 publications

(4 citation statements)

References 31 publications

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“…For SMD processes, specifically the gas tungsten arc welding (GTAW) process, Hoye et al [69] investigated both milling and drilling processes using SMD material. They found that AM Ti-6Al-4V was easier to machine than its wrought counterpart.…”

Section: Wire Fed Directed Energy Depositionmentioning

confidence: 99%

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

Childerhouse

Jackson

2019

Metals

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Near net shape (NNS) manufacturing offers an alternative to conventional processes for the manufacture of titanium alloy components. Compared to the conventional routes, which typically require extensive material removal of forged billets, NNS methods offer more efficient material usage and can significantly reduce machining requirements. Furthermore, NNS manufacturing processes offer benefits such as greater flexibility and reduced costs compared to conventional methods. Processes such as metal additive manufacturing (AM) have started to be adopted in niche applications, most notably for the manufacture of medical implants, where many conventionally forged components have been replaced by those manufactured by AM processes. However, for more widespread adoption of these emerging processes, an improvement in the confidence in the techniques by manufacturers is necessary. This requires addressing challenges such as the limited mechanical properties of parts in their as-built condition compared to wrought products and the post-process machining requirements of components manufactured by these routes. In this review, processes which use a powder or wire feedstock are evaluated to assess their capabilities for the manufacture of titanium alloy components. These processes include powder bed fusion and direct energy deposition metal additive processes as well as hybrid routes, which combine powder metallurgy with thermomechanical post-processing.

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Section: Wire Fed Directed Energy Depositionmentioning

confidence: 99%

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

Childerhouse

Jackson

2019

Metals

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“…However, the parts produced by AM cannot be used or assembled directly. This is because the surface integrity of SLMed parts is poor, specifically, the surface roughness, hardness and residual stress of the SLMed surface are even higher than the wrought material [7]. Therefore, the surface material of the parts should be removed by conventional cutting processes in order to obtain acceptable surface finish.…”

Section: Introductionmentioning

confidence: 99%

Machinability Analysis of Finish-Turning Operations for Ti6Al4V Tubes Fabricated by Selective Laser Melting

Rashid

Ding

et al. 2022

Metals

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With the advent of additive manufacturing as an advanced technology for the fabrication of titanium components, there is a pressing need to investigate the machinability of parts produced using these techniques compared to components made with conventional wrought methodologies. The motivation for this study was to investigate the influences of machining parameters, especially cutting depth, on the machinability of selective laser melted (SLMed) Ti6Al4V tubes, by analyzing the cutting responses, including cutting forces, machined surface roughness and tool wear at varying cutting parameters. Generally, it can be inferred that specific cutting tools used to machine wrought titanium components can also be used for SLMed parts when carrying out finish-machining operations. Cutting forces in the machining of SLMed workpieces could be up to 70% higher than those in machining the wrought counterparts. In contrast, the tool-wear analysis correspondingly showed larger tool-workpiece engagement area on the tool rake face for tools used for machining wrought parts. Adhesion on the cutting edge in the form of built-up edge and attrition of the tool surface were found to be the two most dominant tool-wear mechanisms, and the oxidation condition of the tool surface in machining SLMed parts was more severe (about 8% and 21%). Vibration analysis was also carried out, but no significant difference between the SLMed and wrought workpieces was observed, and the quality of the machined surface was similar.

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“…Greitemeier et al 11 investigated the influence of surface roughness on fatigue life as the fatigue properties of DMLS and EBM Ti-6Al-4V are highly influenced by surface roughness for which a simple model has been formulated. Hoye et al 12 investigated the machinability of gas tungsten arc welding (GTAW) additive manufactured Ti-6Al-4V structures through drilling and milling operation. The cutting force during milling has been 13%-21% low as compared to wrought T-filet structures.…”

Section: Introductionmentioning

confidence: 99%

Study on machinability characteristics of novel additive manufactured titanium alloy (Ti-6Al-4V) fabricated by direct metal laser sintering

Sahoo

Routara

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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The pressing demand of Ti-6Al-4V (grade 5) in aerospace, medical, marine, and chemical processing industries has gained momentum in recent years due to its excellent properties such as high strength to weight ratio and corrosion resistance, bio-compatibility and a common material for additive manufacturing. Additive manufactured Ti-6Al-4V have higher mechanical properties as compared to wrought alloys due to difference in microstructure that negatively influences the machinability characteristics and also lacks ductility. The main limitation of fabricated additive manufactured (AMed) component is the poor surface quality, staircase effect and adhering of non-melted powder particles to the fabricated components. Again, fatigue life of components increases with decrease of surface roughness. Therefore the need of machining of AMed titanium alloys in recent years are gaining importance to eliminate these problems so that desired surface quality and tolerances can be achieved. Therefore the objective of the study is to develop additive manufactured Ti-6Al-4V through direct metal laser sintering process and investigate its machinability characteristics under flood cooling environment with respect to responses as tool wear, surface roughness, cutting temperature, and chip morphology. As most of the heat generated at the interfaces has been carried away through flood cooling, the rate of growth of tool wear, cutting temperature, surface roughness, and degree of serration decreases and thus makes the performance of AMed Ti alloys are comparable with wrought Ti alloys. The dominant tool wear mechanism during machining AMed Ti alloy have been found to be abrasion, chipping, adhesion, BUE, chemical interaction between titanium and cutting tool materials, coating delamination. Optimal parameters for multi-responses are 0.1 mm depth of cut, 0.1 mm/rev feed rate, and 70 m/min cutting speed and improved. Mathematical models are said to be significant and fitted well. Because of the improved machinability, AMed Ti alloys find itself suitable in industrial applications.

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Machining of GTAW additively manufactured Ti-6Al-4V structures

Cited by 14 publications

References 31 publications

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

Machinability Analysis of Finish-Turning Operations for Ti6Al4V Tubes Fabricated by Selective Laser Melting

Study on machinability characteristics of novel additive manufactured titanium alloy (Ti-6Al-4V) fabricated by direct metal laser sintering

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