Electron beam melting of gamma titanium aluminide and investigating the effect of EBM layer orientation on milling performance

Anwar, Saqib; Ahmed, Naveed; Abdo, Basem M. A.; Pervaiz, Salman; Chowdhury, M. A. K.; Al‐Ahmari, Abdulrahman

doi:10.1007/s00170-018-1802-7

Cited by 19 publications

(14 citation statements)

References 33 publications

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“…In both cases, very high roughness was observed. Although some studies have been performed regarding minimizing the roughness of Ti6Al4V components produced by the process of EBM, there is still a need for secondary processing to decrease the high surface roughness (Ra ≈ 20 µm) of the EBM parts [25]. Biffi et al [26] studied the effects of different EBM scanning strategies (factory parameters, full-hatch, full contour in-out, and out-in strategy) on the microstructure, surface morphology, relative density, and mechanical properties of theTi6Al4V EBM parts along the two principal orientations (XZ and XY planes).…”

Section: Introductionmentioning

confidence: 99%

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On the Effect of Electron Beam Melted Ti6Al4V Part Orientations during Milling

Dabwan

Anwar

Al-Samhan

et al. 2020

Metals

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The machining of the electron beam melting (EBM) produced parts is a challenging task because, upon machining, different part orientations (EBM layers’ orientations) produce different surface quality even when the same machining parameters are employed. In this paper, the EBM fabricated parts are machined in three possible orientations with regard to the tool feed direction, where the three orientations are “tool movement in a layer plane” (TILP), “tool movement perpendicular to layer planes” (TLP), and “tool movement parallel to layers planes” (TPLP). The influence of the feed rate, radial depth of cut, and cutting speed is studied on surface roughness, cutting force, micro-hardness, microstructure, chip morphology, and surface morphology of Ti6Al4V, while considering the EBM part orientations. It was found that different orientations have different effects on the machined surface during milling. The results show that the EBM parts can achieve good surface quality and surface integrity when milled along the TLP orientation. For instance, surface roughness (Sa) can be improved up to 29% when the milling tool is fed along the TLP orientation compared to the other orientations (TILP and TPLP). Furthermore, surface morphology significantly improves with lower micro-pits, redeposited chips, and feed marks in case of the TLP orientation.

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Section: Introductionmentioning

confidence: 99%

“…Furthermore, the machining analysis was only limited to the surface roughness. Another study was reported on the milling of the γ-TiAl EBM parts by Anwar et al [25]. They considered the effect of the EBM part orientations during milling on the machined surface roughness and morphology, and edge chipping.…”

Section: Introductionmentioning

confidence: 99%

On the Effect of Electron Beam Melted Ti6Al4V Part Orientations during Milling

Dabwan

Anwar

Al-Samhan

et al. 2020

Metals

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“…However, no previous work has focused on achieving the L-PBF 316L SS parts surface quality by using a machining process with an emphasis on the L-PBF parts orientations with regard to the tool feed direction (TFD). Other studies have been reported on the milling of electron beam melted (EBM) γ-TiAl and Ti6Al4V parts by [ 43 , 44 ]. They reported that the different EBM part orientations during machining can generate various surface roughness even with the same machining parameters.…”

Section: Introductionmentioning

confidence: 99%

Investigations on the Effect of Layers’ Thickness and Orientations in the Machining of Additively Manufactured Stainless Steel 316L

et al. 2021

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Laser-powder bed fusion (L-PBF) process is a family of modern technologies, in which functional, complex (3D) parts are formed by selectively melting the metallic powders layer-by-layer based on fusion. The machining of L-PBF parts for improving their quality is a difficult task. This is because different component orientations (L-PBF-layer orientations) produce different quality of machined surface even though the same cutting parameters are applied. In this paper, stainless steel grade SS 316L parts from L-PBF were subjected to the finishing (milling) process to study the effect of part orientations. Furthermore, an attempt is made to suppress the part orientation effect by changing the layer thickness (LT) of the parts during the L-PBF process. L-PBF parts were fabricated with four different layer thicknesses of 30, 60, 80 and 100 μm to see the effect of the LT on the finish milling process. The results showed that the layer thickness of 60 μm has significantly suppressed the part orientation effect as compared to the other three-layer thicknesses of 30, 80 and 100 μm. The milling results showed that the three-layer thickness including 30, 80 and 100 μm presented up to a 34% difference in surface roughness among different part orientations while using the same milling parameters. In contrast, the layer thickness of 60 μm showed uniform surface roughness for the three-part orientations having a variation of 5–17%. Similarly, the three-layer thicknesses 30, 80 and 100 μm showed up to a 25%, 34% and 56% difference of axial force (Fa), feed force (Ff) and radial force (Fr), respectively. On the other hand, the part produced with layer thickness 60 μm showed up to 11%, 25% and 28% difference in cutting force components Fa, Ff and Fr, respectively. The three-layer thicknesses 30, 80 and 100 μm in micro-hardness were found to vary by up to 14.7% for the three-part orientation. Negligible micro-hardness differences of 1.7% were revealed by the parts with LT 60 μm across different part orientations as compared to 6.5–14% variations for the parts with layer thickness of 30, 80 and 100 μm. Moreover, the parts with LT 60 μm showed uniform and superior surface morphology and reduced edge chipping across all the part orientations. This study revealed that the effect of part orientation during milling becomes minimum and improved machined surface integrity is achieved if the L-PBF parts are fabricated with a layer thickness of 60 μm.

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“…For example, according to research conducted by Sidambe [ 6 ], electron beam melting allows for obtaining a range of surface roughness R a values between 15.8 µm and 54.3 µm which are considered as considerably high. In another study presented by Anwar et al [ 7 ], a surface roughness of additively manufactured parts is reported as R a = 31 µm. These surface roughness values are very high since Klocke et al [ 8 ] and Uddin [ 9 ] stated that the parts used in aerospace and biomedical applications have substantially low surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin

et al. 2020

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Titanium-aluminium-vanadium (Ti 6Al 4V) alloys, nickel alloys (Inconel 718), and duraluminum alloys (AA 2000 series) are widely used materials in numerous engineering applications wherein machined features are required to having good surface finish. In this research, micro-impressions of 12 µm depth are milled on these materials though laser milling. Response surface methodology based design of experiment is followed resulting in 54 experiments per work material. Five laser parameters are considered naming lamp current intensity (I), pulse frequency (f), scanning speed (V), layer thickness (LT), and track displacement (TD). Process performance is evaluated and compared in terms of surface roughness through several statistical and microscopic analysis. The significance, strength, and direction of each of the five laser parametric effects are deeply investigated for the said alloys. Optimized laser parameters are proposed to achieve minimum surface roughness. For the optimized combination of laser parameters to achieve minimum surface roughness (Ra) in the titanium alloy, the said alloy consists of I = 85%, f = 20 kHz, V = 250 mm/s, TD = 11 µm, and LT = 3 µm. Similarly, optimized parameters for nickel alloy are as follows: I = 85%, f = 20 kHz, V = 256 mm/s, TD = 8 µm, and LT = 1 µm. Minimum roughness (Ra) on the surface of aluminum alloys can be achieved under the following optimized parameters: I = 75%, f = 20 kHz, V = 200 mm/s, TD = 12 µm, and LT = 3 µm. Micro-impressions produced under optimized parameters have surface roughness of 0.56 µm, 2.46 µm, and 0.54 µm on titanium alloy, nickel alloy, and duralumin, respectively. Some engineering applications need to have high surface roughness (e.g., in case of biomedical implants) or some desired level of roughness. Therefore, validated statistical models are presented to estimate the desired level of roughness against any laser parametric settings.

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Electron beam melting of gamma titanium aluminide and investigating the effect of EBM layer orientation on milling performance

Cited by 19 publications

References 33 publications

On the Effect of Electron Beam Melted Ti6Al4V Part Orientations during Milling

On the Effect of Electron Beam Melted Ti6Al4V Part Orientations during Milling

Investigations on the Effect of Layers’ Thickness and Orientations in the Machining of Additively Manufactured Stainless Steel 316L

Achieving the Minimum Roughness of Laser Milled Micro-Impressions on Ti 6Al 4V, Inconel 718, and Duralumin

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