Electron beam melting of titanium alloy and surface finish improvement through rotary ultrasonic machining

Ahmed, Naveed; Abdo, Basem M. A.; Darwish, S.M.; Moiduddin, Khawaja; Pervaiz, Salman; Al‐Ahmari, Abdulrahman; Naveed, Madiha

doi:10.1007/s00170-017-0365-3

Cited by 34 publications

(17 citation statements)

References 29 publications

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“…Indeed, during the EBM process, all the powder bed was pre-heated at 1000°C. This may sinter the unmelted or partially-melted powder particles onto the surface, as showed by Ahmed et al [61] on Ti-6Al-4 V. Therefore, The Skewness parameter (Ssk) describes the asymmetry of the height distribution from the mean line. A positive value indicates a surface composed of mainly peaks and few valley, whereas a negative value which indicates a surface mainly composed of deep stripes.…”

Section: Microstructures and Roughness Comparisonmentioning

confidence: 96%

High temperature oxidation of IN 718 manufactured by laser beam melting and electron beam melting: Effect of surface topography

2018

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A B S T R A C TThe oxidation behaviour of IN 718 alloys produced by laser beam melting and electron beam melting was compared to that of the wrought alloy at 850°C in laboratory air. Oxide scales of all alloys were similar in nature and morphology with small differences due to powder particles sintered on the surface of additive manufacturing parts. Nevertheless, major differences in surface topography were noticed, these could affect surface area estimations and consequentlymass gain estimations. A quantitative correlation was determined between apparent parabolic rate constant and surface area.

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Section: Microstructures and Roughness Comparisonmentioning

confidence: 96%

High temperature oxidation of IN 718 manufactured by laser beam melting and electron beam melting: Effect of surface topography

2018

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“…EBM produces components in a vacuum environment and is capable of manufacturing a fully dense part of a series of important engineering alloys directly from a computer‐aided design (CAD) model . It has a broad range of advantages, such as the use of net‐shape processing to produce complex shapes and minimal processing steps, making EBM an attractive alternative for the production of titanium components, particularly those with complex shapes . Since EBM is a complex metallurgical process which significantly includes micro‐zone melting, the microstructure of EBM‐produced components contrasts with the ultrafine and equiaxed grained composite microstructure by sintering and crystallizing of amorphous powder and the bimodal ultrafine lamellar eutectic microstructure in titanium alloys by semi‐solid sintering .…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing of Titanium Alloys by Electron Beam Melting: A Review

et al. 2017

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Electron beam melting (EBM), as one of metal additive manufacturing technologies, is considered to be an innovative industrial production technology. Based on the layer-wise manufacturing technique, as-produced parts can be fabricated on a powder bed using the 3D computational design method. Because the melting process takes place in a vacuum environment, EBM technology can produce parts with higher densities compared to selective laser melting (SLM), particularly when titanium alloy is used. The ability to produce higher quality parts using EBM technology is making EBM more competitive. After briefly introducing the EBM process and the processing factors involved, this paper reviews recent progress in the processing, microstructure, and properties of titanium alloys and their composites manufactured by EBM. The paper describes significant positive progress in EBM of all types of titanium in terms of solid bulk and porous structures including Ti-6Al-4V and Ti-24Nb-4Zr-8Sn, with a focus on manufacturing using EBM and the resultant unique microstructure and service properties (mechanical properties, fatigue behaviors, and corrosion resistance properties) of EBM-produced titanium alloys.

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“…Moreover, thanks to preheating, components produced by EB-PBF are subject to lower thermal gradients, and as a consequence they are characterized by moderate onset of micro-fractures due to thermal variations, and limited residual stresses due to not uniform heating [16]. On the other hand, EB-PBF manufactured components suffer with poor surface quality due to rough finishing [17]. In any case, manufactured parts produced by melting of a powder bed are characterized by lack of fusion defects generated during the production process and by entrapped gas porosity inside powder particles.…”

Section: Introductionmentioning

confidence: 99%

Tensile and Creep Properties Improvement of Ti-6Al-4V Alloy Specimens Produced by Electron Beam Powder Bed Fusion Additive Manufacturing

Aliprandi

Giudice

Guglielmino

et al. 2019

Metals

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Thanks to their excellent mechanical strength in combination with low density, high melting point, and good resistance to corrosion, titanium alloys are very useful in many industrial and biomedical fields. The new additive manufacturing methods, such as Electron Beam Powder Bed Fusion based on the deposition of metal powders layers progressively molten by electron beam scanning, can overcome many of the machining problems concerning the production of peculiar shapes made of Ti alloys. However, the processing route is strictly determinant for mechanical performance of products, especially in the case of Ti alloys. In the present work flat specimens made of Ti-6Al-4V alloy produced by Electron Beam Powder Bed Fusion (or Electron Beam Melting) have been built and post-processed with the purpose of obtaining good tensile and creep performance. Preliminarily, the process parameters were set according to literature evidence and machine producer recommendations, validated by the results of a thermal analysis, aimed at satisfying the best processing conditions to reduce defects, as unmelted regions, microstructure coarsening or porosity, that are detrimental to mechanical behavior. Subsequently, Hot Isostatic Pressing and surface smoothing were considered, respectively, in order to reduce any internal porosity and lower roughness. Microstructure of the investigated specimens was characterized by optical and scanning electron microscopy observations and by X-ray diffraction measurements. Results show enhanced tensile behavior after the hot pressing treatment that allows to relieve stresses and reduce defects detrimental to mechanical properties. The best ductility was obtained by the combined effects of machining and densification. Creep test results verify the beneficial effects of surface smoothing.

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Electron beam melting of titanium alloy and surface finish improvement through rotary ultrasonic machining

Cited by 34 publications

References 29 publications

High temperature oxidation of IN 718 manufactured by laser beam melting and electron beam melting: Effect of surface topography

High temperature oxidation of IN 718 manufactured by laser beam melting and electron beam melting: Effect of surface topography

Additive Manufacturing of Titanium Alloys by Electron Beam Melting: A Review

Tensile and Creep Properties Improvement of Ti-6Al-4V Alloy Specimens Produced by Electron Beam Powder Bed Fusion Additive Manufacturing

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