Variations in the Surface Integrity of Ti-6Al-4V by Combinations of Additive and Subtractive Manufacturing Processes

Bejjani, Roland; Bamford, Erik; Cedergren, Stefan; Archenti, Andreas; Rashid, Amir

doi:10.3390/ma13081825

Cited by 16 publications

(10 citation statements)

References 51 publications

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“…Pores serve as stress risers that are brittle fractures and that increase the susceptibility to failure [ 39 ]. Several studies have shown that advanced tools can help detect faults or other defects that occur in the welding process such as ultrasonic non-destructive testing (NDT) techniques [ 30 ], X-ray CT methods [ 35 , 42 ], and radiographic testing (RT) [ 43 , 44 ]. The slow welding speeds and the welding in the flat position, or uphill in the vertical position, encourage the escape of pores [ 45 ].…”

Section: Discussionmentioning

confidence: 99%

Experimental Investigation of Additive Manufacturing Using a Hot-Wire Plasma Welding Process on Titanium Parts

2021

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In this paper, we propose hot-wire plasma welding, a combination of the plasma welding (PAW) process and the hot-wire process in the additive manufacturing (AM) process. Generally, in plasma welding for AM processes, the deposit grain size increases, and the hardness decreases as the wall height increases. The coarse microstructure, along with the large grain size, corresponds to an increase in deposit temperature, which leads to poorer mechanical properties. At the same time, the hot-wire laser process seems to contain an overly high interstitial amount of oxygen and nitrogen. With an increasing emphasis on sustainability, the hot-wire plasma welding process offers significant advantages: deeper and narrow penetration than the cold-wire plasma welding, improved design flexibility, large deposition rates, and low dilution percentages. Thus, the hot-wire plasma welding process was investigated in this work. The wire used in the welding process was a titanium American Welding Society (AMS) 4951F (Grade 2) welding wire (diameter 1.6 mm), in which the welding was recorded in real time with a charge-coupled device camera (CCD camera). We studied three parameters of the hot-wire plasma welding process: (1) the welding speed, (2) wire current, and (3) wire feeding speed. The mechanical and physical properties (porosity, Vickers hardness, microstructure, and tensile strength) were examined. It was found that the number of layers, the length and width of the molten pool, and the width of the deposited bead increased, while the height of the layer increased, and the hot-wire current played an important role in the deposition. In addition, these results were benchmarked against specimens created by a hot-wire plasma welding/wire-based additive manufacturing process with an intention to develop the hot-wire PAW process as a potential alternative in the additive manufacturing industry.

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Section: Discussionmentioning

confidence: 99%

Experimental Investigation of Additive Manufacturing Using a Hot-Wire Plasma Welding Process on Titanium Parts

2021

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“…It may be characterized as a very difficult-to-cut material due to its endurance and relative elongation (6–15%). Moreover, low heat transfer ability causes that the thermal energy does not dissipate easily by conduction, which results in increase of temperatures in the cutting contact area [ 11 ]. A similar situation takes place in the case of cobalt alloys [ 12 ].…”

Section: Introductionmentioning

confidence: 99%

Effect of Yttrium and Rhenium Ion Implantation on the Performance of Nitride Ceramic Cutting Tools

et al. 2020

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In the paper, the results of experimental investigations of ion implanted cutting tools performance are presented. The tools, made out of Si3N4 with additives typically used for turning of Ti-6Al-4V alloy, underwent implantation with ions of yttrium (Y+) and rhenium (Re+) using the metal vapor vacuum arc method. Distribution of ions on the tool surface was measured. The cutting tools were tested in turning process with measurement of cutting forces and analysis of wear. A rather unexpected result was the increased wear of the tool after Y+ implantation with 1 × 1017 ion/cm2. It was demonstrated, however, that the tool after Y+ 2 × 1017 ion/cm2 ion implantation provided the best machining performance.

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“…The reduced wear at lower cutting speeds suggests a longer separation time at lower cutting speeds, which is reduced when the cutting speed is increased. As discussed previously, the main wear in cutting titanium is the adhesion and diffusion wear, caused by the constant friction between tool and workpiece [51]. The in UAT.…”

Section: Tool Wearmentioning

confidence: 90%

“…The length of cut used for all experiments was 15 mm along the axis of the workpiece in the feed direction. The main wear when cutting titanium is the adhesion and diffusion wear [51]. Adhesion is caused by the high cutting temperature and the constant contact and friction between the tool and the workpiece [44].…”

Section: Tool Wearmentioning

confidence: 99%

“…The cutting temperature when cutting titanium alloys has a major effect on the hardness of the workpiece and consequently the cutting forces. The engineering stresses of titanium are reduced when the temperature increases [51].The increase in the cutting temperature in UAT reduces the stresses needed to strain the titanium alloy and to plastically deform it. This results in reducing the tensile stress of titanium and the cutting forces needed to deform it.…”

Section: Thermal Effectmentioning

confidence: 99%

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Experimental and Numerical Investigation of the Ultrasonic Assisted Turning of Aerospace Alloys. (c2021)

Bachir¹

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The rise in need for aerospace production is directly impacted by the machinability of materials used in aerospace parts. The Ultrasonic Assisted Turning is steadily becoming a research focus as an eco-friendly and cost-efficient unconventional machining method. It has been shown to enhance the machinability of various materials by creating a separation between the tool and the workpiece. The increase in demand for aerospace production created a need for a better understanding of this method’s effect on the machinability of aerospace materials. This research investigates the effect of the Ultrasonic Assisted Turning method on aerospace titanium alloy Ti-6Al-4V and low carbon steel A36. The effect of adding a cryogenic coolant to the ultrasonic machining of titanium alloys is also investigated. The investigation focuses on the variation of the cutting parameters, where the cutting speed and the depth of cut are varied to determine their effect on the machinability of the aerospace materials in Ultrasonic Assisted Turning. The study begins with experimental investigation of the cutting forces and surface roughness for different cutting parameters. Tool wear analysis is then conducted for the optimal cutting parameters. The separation is then investigated theoretically. A Finite Element Model (FEM) is then developed to simulate the cutting conditions and investigate the processes involved in Ultrasonic Assisted Turning for a better understanding of its effect on the machinability of titanium and steel alloys. It is shown that the smallest cutting speed and depth of cut lead to the largest reduction in the cutting forces and enhancement in tool wear whereas the largest cutting speed resulted in the largest reduction in surface roughness. The Ultrasonic Assisted Turning was found to decrease adhesion and microchipping. The theoretical investigation proves the presence of separation. The theoretical and the FEM results show that the separation duration decreases as the cutting speed and depth of cut increase. The temperature, strain rate and stress profiles are extracted from the FEM and are used to provide a better understanding of the ultrasonic effect on the machinability of these alloys. The combined effect of the strain rates and temperature is dominated by the softening caused by the increase in temperature. The addition of a coolant is shown to limit the benefits of this method. This research provides a better understanding of the beneficial effect of the Ultrasonic Assisted Turning on the machinability of titanium and steel alloys.’

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Variations in the Surface Integrity of Ti-6Al-4V by Combinations of Additive and Subtractive Manufacturing Processes

Cited by 16 publications

References 51 publications

Experimental Investigation of Additive Manufacturing Using a Hot-Wire Plasma Welding Process on Titanium Parts

Experimental Investigation of Additive Manufacturing Using a Hot-Wire Plasma Welding Process on Titanium Parts

Effect of Yttrium and Rhenium Ion Implantation on the Performance of Nitride Ceramic Cutting Tools

Experimental and Numerical Investigation of the Ultrasonic Assisted Turning of Aerospace Alloys. (c2021)

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