Machinability of SLM-produced Ti6Al4V titanium alloy parts

Al-Rubaie, Kassim S.; Melotti, Saulo; Rabelo, Alexsandro; Paiva, José Mario; Elbestawi, M.A.

doi:10.1016/j.jmapro.2020.07.035

Cited by 84 publications

(30 citation statements)

References 33 publications

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“…In Figure 9a for axial force, there is a significant difference of almost 57% between the highest cutting force in the case of TLP and the lowest value TILP, and there is a difference of almost 42% between TPLP and TLP orientations. The cutting force results in axial force for TILP are consistent with those found by Al-Rubaie et al [37] via milling of the SLM Ti6Al4V part. It appears that increased cutting force results in decreased surface roughness, as presented in Figure 6 in Section 3.2.…”

Section: Cutting Force Evaluationsupporting

confidence: 89%

“…These chips affect the cutting forces and temperatures in the machining process, and also the workpiece surface quality as explained in Calamaz et al [58]. Discontinuous chips are produced during milling of the EBM Ti6Al4V part for three orientations, which are consistent with those found by Al-Rubaie et al [37] during the milling of the SLM Ti6Al4V part. Chip formation studies are conducted for the three-part orientations at different milling parameters.…”

Section: Chip Morphology Evaluationsupporting

confidence: 81%

“…The surface roughness (Sa) of the EBM parts after milling vary between 0.11 and 0.17 µm. Similar roughness values after milling of conventional Ti6Al4V were achieved by Ginta et al [35], Zhang and Li [36], and Al-Rubaie et al [37]. The average roughness of the surface (Sa) is much lower when the tool movement is perpendicular to layer planes (TLP) than that the other two orientations (TPLP, and TILP).…”

Section: Surface Roughness Evaluationsupporting

confidence: 75%

“…Al-Rubaie et al [37] evaluated the machinability of as-fabricated SLM Ti6Al4V parts (SLM-AB), stress-relief SLM parts (SLM-SR) and conventional Ti6Al4V parts on surface roughness, cutting force, tool wear, and chip morphology via milling. They concluded that the cutting parameters used to machine the conventionally Ti6Al4V alloy are also valid for machining the SLM Ti6Al4V alloy.…”

Section: Introductionmentioning

confidence: 99%

“…However, this study did not consider the effect of the SLM part orientations during milling. Hassanin et al [37] introduced a hybrid microfabrication technology that combines both the freedom design of SLM and the high surface quality of microwire electrical discharge machining (µ-WEDM). Their aim was to manufacture high-quality micro implantable components with the highest density and the best surface quality.…”

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: Cutting Force Evaluationsupporting

confidence: 89%

Section: Chip Morphology Evaluationsupporting

confidence: 81%

Section: Surface Roughness Evaluationsupporting

confidence: 75%

Section: Introductionmentioning

confidence: 99%

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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Comparing the Cold, Warm, and Hot Deformation Flow Behavior of Selective Laser‐Melted and Electron‐Beam‐Melted Ti–6Al–2Sn–4Zr–2Mo Alloy

Roshani,

Abedi,

Saboori

2023

Adv Eng Mater

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The cold, warm, and hot deformation flow behavior and mechanical properties of the Ti‐6242 alloy produced by selective laser melting (SLM) and electron beam melting (EBM) are compared. Hot compression tests are conducted over a wide temperature range (100–1000 °C) at a constant strain rate of 0.001 s−1. The yield and overall strength levels of the SLMed specimens are higher than those of the EBMed specimens at all temperatures. A thermally stable region is observed for SLMed specimens in the temperature range of 100–700 °C, but the strength level drops significantly (approximately 300–500 MPa) at above 700 °C. The stability region shifts to the lower temperature range of 100–600°Cfor the EBMed specimens, and strength starts to decrease at 600 °C. Both specimens experience fracture in a cold‐temperature regime but exhibit a high strain tolerance of approximately 0.4. The SLMed samples display a completely brittle behavior at a warm temperature regime, whereas, the EBMed specimens demonstrate better formability, tolerating higher compressive strains. The softening fraction substantially increases at high temperatures, indicating safe domains for thermomechanical processing of additively manufactured Ti6242 alloy.

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