Anisotropy effect of additively manufactured Ti6Al4V titanium alloy on surface quality after milling

Lizzul, Lucia; Sorgato, Marco; Bertolini, Rachele; Ghiotti, Andrea

doi:10.1016/j.precisioneng.2020.10.003

Cited by 37 publications

(12 citation statements)

References 34 publications

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“…In [21] a 3D Finite Element-based model was developed to predict the surface integrity of the EBM Ti6Al4V after dry and cryogenic machining: to do that, the thickness of the alpha lamellae that characterize the microstructure of the AM metal was predicted by means of an empirical model calibrated through experimental data. It was found a good agreement between the experimental and numerical nano-elsew here [6,9,26] and it is alike comparable to the results obtained for forged Ti64 material [1] . Tw o run-outs w ere obtained at 600 M Pa and 775 M Pa.…”

Section: Modelling and Control Of Post-am Machiningsupporting

confidence: 79%

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Machining of Additive Manufactured Metal Alloys

Bruschi

Bertolini

Ghiotti

2022

KEM

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Additive Manufacturing of metal alloys offers unique advantages for producing net-shape components of complex geometries with very little waste of material. Nevertheless, machining operations may be needed on functional surfaces to get the required surface finish and geometrical tolerances. This poses challenging issues since the microstructural features characterizing the AM alloys are drastically different from those of the wrought alloys of the same chemical composition, which, in turn, may affect the mechanical and machining response to a great extent. This paper shows that both the machined surface integrity and tool wear are greatly affected by the microstructural features induced by the previous AM process as well as by the build-up orientation.

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Section: Modelling and Control Of Post-am Machiningsupporting

confidence: 79%

“…1). A follow-up of this study in [6] showed the effect of the AM-induced anisotropy also on the machined surface integrity, proving Achievements and Trends in Material Forming that samples fabricated with horizontal orientation allowed for better machinability (see for example the results about the burr height on the right of Fig. 1).…”

Section: Machinabilitysupporting

confidence: 53%

Machining of Additive Manufactured Metal Alloys

Bruschi

Bertolini

Ghiotti

2022

KEM

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“…Bonati et al [50] as well as Hojati et al [47] observed that when micro milling parts made of Ti6Al4V, the additively manufactured (laser-engineered net shaping (LENS), respectively; electron beam melting (EBM)) parts showed significantly more burr formation than the extruded parts despite their higher hardness. Hojati et al [47] concluded, in agreement with Lizzul et al [51] as well as Khaliq et al [52], that other factors related to the microstructure of the material may have an essential role in burr formation. Our reference material exhibits a significantly coarser microstructure than the L-PBF AlSi10Mg (Fig.…”

Section: Burrssupporting

confidence: 53%

Analysis of the machinability when milling AlSi10Mg additively manufactured via laser-based powder bed fusion

Zimmermann

Müller

Kirsch

et al. 2020

Int J Adv Manuf Technol

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Laser-based powder bed fusion (L-PBF) is a promising technology for the production of near net–shaped metallic components. The high surface roughness and the comparatively low-dimensional accuracy of such components, however, usually require a finishing by a subtractive process such as milling or grinding in order to meet the requirements of the application. Materials manufactured via L-PBF are characterized by a unique microstructure and anisotropic material properties. These specific properties could also affect the subtractive processes themselves. In this paper, the effect of L-PBF on the machinability of the aluminum alloy AlSi10Mg is explored when milling. The chips, the process forces, the surface morphology, the microhardness, and the burr formation are analyzed in dependence on the manufacturing parameter settings used for L-PBF and the direction of feed motion of the end mill relative to the build-up direction of the parts. The results are compared with a conventionally cast AlSi10Mg. The analysis shows that L-PBF influences the machinability. Differences between the reference and the L-PBF AlSi10Mg were observed in the chip form, the process forces, the surface morphology, and the burr formation. The initial manufacturing method of the part thus needs to be considered during the design of the finishing process to achieve suitable results.

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“…Anisotropy is defined as non-homogeneity concerning the microstructure and properties after EBM processing. It is usually caused by the orientation of the voids, difference in loading directions, weak layers of the grain boundary and temperature variations in EBM (Lizzul et al, 2021). Therefore, chemical homogeneity is usually required to improve the process efficiency.…”

Section: Anisotropic Behaviormentioning

confidence: 99%

“…Different unit cell sizes such as 2-3 mm of Ti64 gyroid structure with porosity range of 82-85% were manufactured by Melchels et al (2010) (Hara et al, 2016), copyright 2016 Elsevier behavior for different material properties. Lizzul et al (2021) concluded that the horizontal orientation of the build parts for Ti64 is better to cope with the formation of columnar grains along the build direction.…”

Section: Anisotropic Behaviormentioning

confidence: 99%

A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants

Ishfaq

Rehman

Khan

et al. 2021

RPJ

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Purpose Human aging is becoming a common issue these days as it results in orthopaedic-related issues such as joints disorderness, bone-fracture. People with age = 60 years suffer more from these aforesaid issues. It is expected that these issues in human beings will ultimately reach 2.1 billion by 2050 worldwide. Furthermore, the increase in traffic accidents in young people throughout the world has significantly emerged the need for artificial implants. Their implantation can act as a substitute for fractured bones or disordered joints. Therefore, this study aims to focus on electron beam melted titanium (Ti)-based orthopaedic implants along with their recent trends in the field. Design/methodology/approach The main contents of this work include the basic theme and background of the metal-based additive manufacturing, different implant materials specifically Ti alloys and their classification based on crystallographic transus temperature (including α, metastable β, β and α + β phases), details of electron beam melting (EBM) concerning its process physics, various control variables and performance characteristics of EBMed Ti alloys in orthopaedic and orthodontic implants, applications of EBMed Ti alloys in various load-bearing implants, different challenges associated with the EBMed Ti-based implants along with their possible solutions. Recent trends and shortfalls have also been described at the end. Findings EBM is getting significant attention in medical implants because of its minor issues as compared to conventional fabrication practices such as Ti casting and possesses a significant research potential to fabricate various medical implants. The elastic modulus and strength of EBMed ß Ti-alloys such as 24Nb-4Zr-8Sn and Ti-33Nb-4Sn are superior compared to conventional Ti for orthopaedic implants. Beta Ti alloys processed by EBM have near bone elastic modulus (approximately 35–50 GPa) along with improved tribo-mechanical performance involving mechanical strength, wear and corrosion resistance, along with biocompatibility for implants. Originality/value Advances in EBM have opened the gateway Ti alloys in the biomedical field explicitly ß-alloys because of their unique biocompatibility, bioactivity along with improved tribo-mechanical performance. Less significant work is available on the EBM of Ti alloys in orthopaedic and orthodontic implants. This study is directed solely on the EBM of medical Ti alloys in medical sectors to explore their different aspects for future research opportunities.

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Anisotropy effect of additively manufactured Ti6Al4V titanium alloy on surface quality after milling

Cited by 37 publications

References 34 publications

Machining of Additive Manufactured Metal Alloys

Machining of Additive Manufactured Metal Alloys

Analysis of the machinability when milling AlSi10Mg additively manufactured via laser-based powder bed fusion

A review on the performance characteristics, applications, challenges and possible solutions in electron beam melted Ti-based orthopaedic and orthodontic implants

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