Predicting surface quality of γ-TiAl produced by additive manufacturing process using response surface method

Al-Ahmari, Abdulrahman; Mohammad, Ashfaq; Alfaify, Abdullah; Abdo, Basem M. A.; Alomar, Abdulrahman; Dawud, Abdelnaser

doi:10.1007/s12206-015-1239-y

Cited by 22 publications

(9 citation statements)

References 29 publications

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“…Al-Ahmari et al [41] studied the effect of the milling process parameters (spindle speed, feed rate, depth of cut, and coolant type) on the surface roughness of γ-TiAl EBM parts. However, this study did not take into account the effect of the EBM part orientations.…”

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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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%

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

Dabwan

Anwar

Al-Samhan

et al. 2020

Metals

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“…As new class of lightweight and high-temperature resistance materials, γ-TiAl alloys have attracted more attention in the aerospace manufacturing fields due to their unique combination of mechanical properties [1]. γ-TiAl is a kind of intermetallic alloys that mainly contains Ti and Al, and adding elements like Cr or Mn to improve ductility and Nb to increase strength and oxidation resistance [2].…”

Section: Introductionmentioning

confidence: 99%

Tool determination and geometry parameter optimization of carbide tool in high-speed milling of third-generation γ-TiAl alloy

Ren

Zhai

Shi

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

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Gamma titanium aluminide alloys (γ-TiAl) are widely recognized as potential replacement for nickel-based superalloys in aerospace. However, along with brittleness at room temperature, poor surface quality and sever tool wear undermine their machinability, so that γ-TiAl alloy is considered as a typical intractable material. Tool selection and geometry optimization are encouraging strategies to improve the machinability of this kind of material. In this work, the cutting performance of six carbide grade tools is compared. And the cutting force, surface roughness and tool wear are selected as the evaluation criterion for the tool material determination. Then, the effects of tool geometry parameters including rake angle, primary relief angle and helix angle on surface roughness and tool wear are further studied. The sample dataset is utilized to formulate the first-order model with interaction. The predicted results of these models accorded well with the measured results. Due to the multi-performance characteristics, grey relational analysis method is introduced into the optimization of tool geometry parameters. The analysis of variance is employed to identify the most significant factor. And then, the confirmation test showed the improvement of the multi-performance characteristics.

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“…At the same time, it was found that for samples electropolished in a bath with ER, many results were lower than 0.5 V SCE , while for samples electropolished in a bath without ER, most of the results exceeded this value. Due to this, the authors decided to analyse the significance of differences between the obtained results with use of data analysis methods used in various types of data evaluation, among others in medicine, chemical analysis, or engineering [31][32][33][34]. e normality analysis with use of the Shapiro-Wilk test did not show a significant deviation from normal distribution.…”

Section: Corrosion Resistance Testsmentioning

confidence: 99%

Electrochemical Reduction of Industrial Baths Used for Electropolishing of Stainless Steel

Lochyński

Charazińska

Łyczkowska-Widłak

et al. 2018

Advances in Materials Science and Engineering

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Long-term exploitation of industrial electropolishing baths may contribute to the emergence of surface defects and may limit the range of applicable current densities. Due to this, extending the time of use of industrial baths is a major challenge. The application of electrochemical reduction in the process of reduction industrial baths enabled to reduce its contamination and, as a result, to enhance the surface quality of electropolished samples of grade 304 stainless steel. The contamination influence of the electropolishing bath on such parameters of the electropolished samples as roughness, gloss, mass reduction, and corrosion resistance was compared. The conducted tests included reduction of the contaminated industrial bath with use of cathodic reduction and monitoring of bath contamination with use of emission spectrometry ICP-OES. Potentiodynamic tests in 0.5 M chlorine environment with the aim to determine the influence of electrochemical reduction of the plating bath on surface resistance demonstrated that the pitting corrosion resistance of samples electropolished in a bath after reduction was reduced by approximately 0.1 V in comparison with samples electropolished before reduction. The calculations conducted for 24 corrosion resistance measurements demonstrated that differences between the results were significant. Bath reduction leads to improved roughness and gloss, even by approximately 500 GU (gloss units). At the same time, mass reduction decreases even by 13% in comparison with the process conducted in the bath before reduction. This may have a positive influence by slowing down the bath contamination process and, as a result, it reduces negative environmental impact. Another argument that supports the reduction of industrial baths is slowing down the process of cathode contamination during the electropolishing process. In industrial conditions, this may extend the possibility to conduct the process without the need for cathode reduction or replacement.

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Predicting surface quality of γ-TiAl produced by additive manufacturing process using response surface method

Cited by 22 publications

References 29 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

Tool determination and geometry parameter optimization of carbide tool in high-speed milling of third-generation γ-TiAl alloy

Electrochemical Reduction of Industrial Baths Used for Electropolishing of Stainless Steel

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