Metallurgical and Machinability Characteristics of Wrought and Selective Laser Melted Ti-6Al-4V

Shunmugavel, Manikandakumar; Polishetty, Ashwin; Nomani, Junior; Goldberg, Moshe; Littlefair, Guy

doi:10.1155/2016/7407918

Cited by 27 publications

(22 citation statements)

References 28 publications

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“…Surface quality of additive manufactured components is often found to be affected by non-uniform distribution of powders, delamination between the layers and rippling effect caused by the shear force of laser on the liquefied powder particles (Yadroitsev and Smurov, 2011). Thus, to eliminate these defects and improve the surface quality of additive manufactured components, a final touch of finish machining is always required (Shunmugavel et al, 2016a(Shunmugavel et al, , 2016b. Machining of titanium alloys is difficult and cumbersome owing to its poor thermal conductivity, work hardening and high chemical reactivity which leads to rapid tool wear and high cutting forces (Ezugwu and Wang, 1997).…”

Section: Introductionmentioning

confidence: 99%

A comparative study of mechanical properties and machinability of wrought and additive manufactured (selective laser melting) titanium alloy – Ti-6Al-4V

Shunmugavel

Polishetty

Goldberg

et al. 2017

RPJ

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Purpose The purpose of this paper is to study and compare the mechanical properties and machinability characteristics of additive manufactured titanium alloy Ti-6Al-4V with conventionally produced wrought titanium alloy,Ti-6Al-4V. The difference in mechanical properties such as yield strength, ultimate tensile strength, micro hardness, percentage of elongation and their effect on machinability characteristics like cutting forces and surface roughness are studied. It was found that higher strength and hardness of SLM Ti-6Al-4V compared to wrought Ti-6Al-4V owing to its peculiar acicular microstructure significantly affected the cutting forces and surface roughness. High cutting forces and low surface roughness were observed during machining of additive manufactured components compared to its wrought counterpart because of their difference in strength, hardness and ductility. Design/methodology/approach Mechanical properties like yield strength, ultimate tensile strength, hardness and percentage of elongation and machinability characteristics like cutting forces and surface roughness were studied for both wrought and additive manufactured Ti-6Al-4V. Findings Mechanical properties like yield strength, ultimate tensile strength and hardness were higher for additive manufactured components as compared to the wrought component. However additive manufactured components significantly lacked in ductility as compared to the wrought parts. Concerning machining, higher cutting forces and lower surface roughness were observed in additive manufactured Ti-6Al-4V compared to the wrought part as a result of differences in mechanical properties of these differently processed materials. Originality/value This paper, for the first time, discusses the machining capabilities of additive manufactured Ti-6Al-4V.

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Section: Introductionmentioning

confidence: 99%

A comparative study of mechanical properties and machinability of wrought and additive manufactured (selective laser melting) titanium alloy – Ti-6Al-4V

Shunmugavel

Polishetty

Goldberg

et al. 2017

RPJ

Self Cite

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“…In particular, during material deposition operations, parts are subjected to high thermal gradients, i.e. high heat and cooling rates, that lead to a higher strength and hardness of the compacted powder and consequently to higher cutting forces and tool wear rates [186]. Milton et al [187] reported that the increase of cutting forces was possibly due to microstructural discontinuities of AM components, which entailed higher wear rates and lower tool life.…”

Section: Materials and Machinabilitymentioning

confidence: 99%

Powder-based laser hybrid additive manufacturing of metals: a review

Jiménez

Bidare

Hassanin

et al. 2021

Int J Adv Manuf Technol

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Recent advances in additive manufacturing (AM) have attracted significant industrial interest. Initially, AM was mainly associated with the fabrication of prototypes, but the AM advances together with the broadening range of available materials, especially for producing metallic parts, have broaden the application areas and now the technology can be used for manufacturing functional parts, too. Especially, the AM technologies enable the creation of complex and topologically optimised geometries with internal cavities that were impossible to produce with traditional manufacturing processes. However, the tight geometrical tolerances along with the strict surface integrity requirements in aerospace, biomedical and automotive industries are not achievable in most cases with standalone AM technologies. Therefore, AM parts need extensive post-processing to ensure that their surface and dimensional requirements together with their respective mechanical properties are met. In this context, it is not surprising that the integration of AM with post-processing technologies into single and multi set-up processing solutions, commonly referred to as hybrid AM, has emerged as a very attractive proposition for industry while attracting a significant R&D interest. This paper reviews the current research and technology advances associated with the hybrid AM solutions. The special focus is on hybrid AM solutions that combine the capabilities of laser-based AM for processing powders with the necessary post-process technologies for producing metal parts with required accuracy, surface integrity and material properties. Commercially available hybrid AM systems that integrate laser-based AM with post-processing technologies are also reviewed together with their key application areas. Finally, the main challenges and open issues in broadening the industrial use of hybrid AM solutions are discussed.

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“…The post-process finish machinability of SLM parts has been investigated in a number of studies [50][51][52]. Shunmugavel et al [50] found that SLM Ti-6Al-4V was more challenging to machine than its wrought counterpart. Both cutting forces and wear rates of a PVD coated tool were found to be significantly greater for the SLM material.…”

Section: Selective Laser Meltingmentioning

confidence: 99%

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

Childerhouse

Jackson

2019

Metals

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Near net shape (NNS) manufacturing offers an alternative to conventional processes for the manufacture of titanium alloy components. Compared to the conventional routes, which typically require extensive material removal of forged billets, NNS methods offer more efficient material usage and can significantly reduce machining requirements. Furthermore, NNS manufacturing processes offer benefits such as greater flexibility and reduced costs compared to conventional methods. Processes such as metal additive manufacturing (AM) have started to be adopted in niche applications, most notably for the manufacture of medical implants, where many conventionally forged components have been replaced by those manufactured by AM processes. However, for more widespread adoption of these emerging processes, an improvement in the confidence in the techniques by manufacturers is necessary. This requires addressing challenges such as the limited mechanical properties of parts in their as-built condition compared to wrought products and the post-process machining requirements of components manufactured by these routes. In this review, processes which use a powder or wire feedstock are evaluated to assess their capabilities for the manufacture of titanium alloy components. These processes include powder bed fusion and direct energy deposition metal additive processes as well as hybrid routes, which combine powder metallurgy with thermomechanical post-processing.

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Metallurgical and Machinability Characteristics of Wrought and Selective Laser Melted Ti-6Al-4V

Cited by 27 publications

References 28 publications

A comparative study of mechanical properties and machinability of wrought and additive manufactured (selective laser melting) titanium alloy – Ti-6Al-4V

A comparative study of mechanical properties and machinability of wrought and additive manufactured (selective laser melting) titanium alloy – Ti-6Al-4V

Powder-based laser hybrid additive manufacturing of metals: a review

Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

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