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The purpose of this study was to compare machining performance between chemical vapor deposition (CVD)- and physical vapor deposition (PVD)-coated cutting tools to obtain the optimal cutting parameters based on different types of tools for machining titanium alloy (Ti-6Al-4V).

The design of the experiment was constructed using the response surface methodology (RSM) with the Box–Behnken method. Two types of round-shaped tungsten carbide inserts were used in this experiment, namely, PVD TiAlN/AlCrN insert tool and CVD TiCN/Al₂O₃ insert tool. The titanium alloy (Ti-6Al-4V) material was used throughout this experiment. The tool wear and microstructure analysis were measured using a tool maker microscope, an optical microscope and a scanning electron machine.

The PVD TiAlN/AlCrN insert tool produces the lowest tool wear that significantly prolongs the cutting tool life compared to the CVD TiCN/Al₂O₃ insert tool. In addition, depth of cut was the main factor affecting the tool life, followed by cutting speed and feed rate.

This study was conducted to compare machining performance between CVD- and PVD-coated cutting tools to obtain the optimal cutting parameters based on different types of tools for machining titanium alloy (Ti-6Al-4V). In addition, the information presented in this paper helps reduce the manufacturing cost and setup time for machining titanium alloy. Finally, tool wear comparison between PVD- and CVD-coated titanium alloys was also presented for future improvement for tool manufacturing application.

The purpose of this paper is to investigate the influence of mechanical surface treatments on the surface layer properties and the fatigue performance of the aircraft alloys Al 7075‐T73 and Ti‐6Al‐4V

Laser peening without coating (LPwC), shot peening (SP), ultrasonic shot peening (USP) and ball burnishing (BB) were applied and the resulting changes in surface roughness and residual stress‐depth profiles were evaluated. Fatigue performance of both alloys was tested in rotating beam loading (R=−1) on hourglass‐shaped specimens and the results were compared with the electrolytically polished (EP) reference conditions.

All studied mechanical surface treatments led to pronounced increases in fully reversed fatigue lives and fatigue strengths in both Al 7075‐T73 and Ti‐6Al‐4V.

To the authors' knowledge, this is the first paper that compares fatigue performance of a wide variety of mechanically surface treated conditions in two aircraft alloys.

Electron-beam welding has been widely used in industry to join different titanium alloys (Ti-6Al-4V) components. During welding production defects, such as porosity, lack of penetration or thinning are often observed. High-cycle fatigue (HCF) tests have been performed on welded specimens to understand the effect of weld defects on fatigue capabilities. The fatigue life of different types of “defective” welds has been compared against a non-welded reference specimen.

The results of the experimental campaign have been correlated with finite elements models.

It is concluded the geometry produced by the weld process, e.g. toe radius and under-bead shape, and the related stress raisers play a relevant role on fatigue capabilities of welds. This conclusion is valid only for a Ti-6Al-4V T-joint weld and only for flaw initiation. Knock down in materials properties has not been considered.

There is a lack of HCF fatigue data for welds of this geometry and material in the open literature. The paper is of relevance for industrial application and practical interest, although a lot more validation tests are required to draw a final conclusion.

Titanium (Ti) alloys are in high demand in manufacturing industries all over the world. The property like high strength to weight ratio makes Ti alloys highly recommended for aerospace industries. Ti alloys possess good weldability, and therefore, they were extensively investigated with regard to strength and metallurgical properties of welded joint. This study aims to deal with the analysis of strength and microstructural changes in Ti-6Al-4V (Grade 5) alloy after tungsten inert gas (TIG) welding.

Two pair of Ti alloy plates were welded in two different voltages, i.e. 24 and 28 V, with keeping the current constant, i.e. 80 A It was a random selection of current and voltage values to check the performance of welded material. Both the welded plates were undergone through some mechanical property analysis like impact test, tensile test and hardness test. In addition, the microstructure of the welded joints was also analyzed.

It was found that hardness and tensile properties gets improved with an increment in voltage, but this effect was reverse for impact toughness. A good corroboration between microstructure and mechanical properties, such as tensile strength, hardness and toughness, was reported in this work. Heat distribution in both the welded plates was simulated through ANSYS software to check the temperature contour in the plates.

A good corroboration between microstructure and mechanical properties, such as tensile strength, hardness and toughness, was reported in this study.

Ti‐6Al‐4V is one of the most attractive materials being used in aerospace, automotive and medical implant industries. Electron beam melting (EBM) is one of the direct digital manufacturing methods to produce complex geometries of fully dense and near net shape parts. The EBM system provides an opportunity to built metallic objects with different processing parameter settings like beam current, scan speed, probe size on powder, etc. The purpose of this paper is to determine and understand the effect of part's thickness and variation in process parameter settings of the EBM system on surface roughness/topography of EBM fabricated Ti‐6Al‐4V metallic parts.

A mathematical model based upon response surface methodology (RSM) is developed to study the variation of surface roughness with changing process parameter settings. Surface roughness of the test slabs produced with different parameter settings and thickness has been studied under confocal microscope. Response surface methodology was used to develop a multiple regression model to correlate the effect of variation in EBM process parameters settings and thickness of parts on surface roughness of EBM produced Ti‐6Al‐4V.

It has been observed that every part produced by EBM system has detectable surface roughness. The surface roughness parameter Ra varies between 1‐20 μm for different samples depending upon the process parameter setting and thickness. The Ra value increases with increasing sample thickness and beam current, and decreases with increase in offset focus and scan speed.

Surface roughness is related to wear and friction property of the material and hence is related to the life time and performance of the part. Surface roughness is an important property of any material to be considered as biomaterial. The surface roughness of the material depends upon the manufacturing method and environment and hence it is controllable either during fabrication or by post processing. From the 1st order regression model developed in this study, it is also evident that sample thickness, scan speed and beam current have relatively more effect on roughness value then the offset focus. With the model obtained equation, a designer can subsequently select the best combination of sample thickness and process parameter values to achieve desired surface roughness.

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding and polishing of additive titanium alloy blades to ensure the surface integrity and machining accuracy of the blades.

At present, robot grinding and polishing are mainstream processing methods in blade automatic processing. This review systematically summarizes the processing characteristics and processing methods of additive manufacturing (AM) titanium alloy blades. On the one hand, the unique manufacturing process and thermal effect of AM have created the unique processing characteristics of additive titanium alloy blades. On the other hand, the robot grinding and polishing process needs to incorporate the material removal model into the traditional processing flow according to the processing characteristics of the additive titanium alloy.

Robot belt grinding can solve the processing problem of additive titanium alloy blades. The complex surface of the blade generates a robot grinding trajectory through trajectory planning. The trajectory planning of the robot profoundly affects the machining accuracy and surface quality of the blade. Subsequent research is needed to solve the problems of high machining accuracy of blade profiles, complex surface material removal models and uneven distribution of blade machining allowance. In the process parameters of the robot, the grinding parameters, trajectory planning and error compensation affect the surface quality of the blade through the material removal method, grinding force and grinding temperature. The machining accuracy of the blade surface is affected by robot vibration and stiffness.

This review systematically summarizes the processing characteristics and processing methods of aviation titanium alloy blades manufactured by AM. Combined with the material properties of additive titanium alloy, it provides a new idea for robot grinding and polishing of aviation titanium alloy blades manufactured by AM.

This study aims to evaluate and assess the elastoplastic properties of Ti-6Al-4V alloy manufactured by Arcam Q20 Plus electron beam melting (EBM) machine by a tensile test campaign and micro computerized tomography (microCT) imaging.

ASTM E8 tensile test specimens are designed and manufactured by EBM at an Arcam Q20 Plus machine. Surface quality is improved by machining to discard the effect of surface roughness. After surface machining, hot isostatic pressing (HIP) post-treatment is applied to half of the specimens to remove unsolicited internal defects. ASTM E8 tensile test campaign is carried out simultaneously with digital image correlation to acquire strain data for each sample. Finally, build direction and HIP post-treatment dependencies of elastoplastic properties are analyzed by F-test and t-test statistical analyses methods.

Modulus of elasticity presents isotropic behavior for each build direction according to F-test and t-test analysis. Yield and ultimate strengths vary according to build direction and post-treatment. Stiffness and strength properties are superior to conventional Ti-6Al-4V material; however, ductility turns out to be poor for aerospace structures compared to conventional Ti-6Al-4V alloy. In addition, micro CT images show that support structure leads to dense internal defects and pores at applied surfaces. However, HIP post-treatment diminishes those internal defects and pores thoroughly.

As a novel scientific contribution, this study investigates the effects of three orthogonal build directions on elastoplastic properties, while many studies focus on only two-build directions. Evaluation of Poisson’s ratio is the other originality of this study. Furthermore, another finding through micro CT imaging is that temporary support structures result in intense defects closer to applied surfaces; hence high-stress regions of structures should be avoided to use support structures.

Human aging is becoming a common issue these days as it results in orthopaedic-related issues such as joints disorderness, bone-fracture. People with age = 60 years suffer more from these aforesaid issues. It is expected that these issues in human beings will ultimately reach 2.1 billion by 2050 worldwide. Furthermore, the increase in traffic accidents in young people throughout the world has significantly emerged the need for artificial implants. Their implantation can act as a substitute for fractured bones or disordered joints. Therefore, this study aims to focus on electron beam melted titanium (Ti)-based orthopaedic implants along with their recent trends in the field.

The main contents of this work include the basic theme and background of the metal-based additive manufacturing, different implant materials specifically Ti alloys and their classification based on crystallographic transus temperature (including α, metastable β, β and α + β phases), details of electron beam melting (EBM) concerning its process physics, various control variables and performance characteristics of EBMed Ti alloys in orthopaedic and orthodontic implants, applications of EBMed Ti alloys in various load-bearing implants, different challenges associated with the EBMed Ti-based implants along with their possible solutions. Recent trends and shortfalls have also been described at the end.

EBM is getting significant attention in medical implants because of its minor issues as compared to conventional fabrication practices such as Ti casting and possesses a significant research potential to fabricate various medical implants. The elastic modulus and strength of EBMed ß Ti-alloys such as 24Nb-4Zr-8Sn and Ti-33Nb-4Sn are superior compared to conventional Ti for orthopaedic implants. Beta Ti alloys processed by EBM have near bone elastic modulus (approximately 35–50 GPa) along with improved tribo-mechanical performance involving mechanical strength, wear and corrosion resistance, along with biocompatibility for implants.

Advances in EBM have opened the gateway Ti alloys in the biomedical field explicitly ß-alloys because of their unique biocompatibility, bioactivity along with improved tribo-mechanical performance. Less significant work is available on the EBM of Ti alloys in orthopaedic and orthodontic implants. This study is directed solely on the EBM of medical Ti alloys in medical sectors to explore their different aspects for future research opportunities.

In this research, electro discharge machining (EDM) of Ti-5Al-2.5Sn titanium alloy is performed taking gap voltage, pulse on time, peak current and duty cycle as process parameters. The purpose of this paper is to find out the optimal process parameters setting for getting higher machining efficiency.

For experimental design, a face-centered central composite design (FCCCD)-based response surface methodology (RSM) is used. Multi-objective optimization like grey relational analysis (GRA) is adopted to achieve the higher machining efficiency by means of lower radial overcut (ROC), surface roughness (Ra), tool wear rate (TWR) and higher material removal rate (MRR). For the statistical study, analysis of variance (ANOVA) has been carried out.

The result shows that gap voltage, peak current and pulse on time are the most efficient parameters for the responses. An optimal parameter setting has been obtained for achieving higher machining efficiency. For validation of the study, confirmation experiment has been performed at optimal parameters setting.

Optimum parameter level for higher machining performance of Ti-5Al-2.5Sn Titanium alloy has been achieved machined by copper electrode during EDM operation.

The purpose of this paper is to explore the basic loading state in local loading forming process of large-sized complicated rib-web component, which is important for understanding process characteristic, controlling metal flow and designing preformed geometry of the local loading forming process. Moreover the analytical models for different loading states are established to quickly predict the metal flow.

Through analysis of geometric characteristic of large-sized complicated rib-web component and the deformation characteristic on planes of metal flow by local loading method, a representative cross-section is put forward and designed, which could reflect the local loading forming characteristics of large-sized complicated rib-web component. Finite element method (FEM) is used to analyze the stress and metal flow, and the analytical models of metal flow are established by using slab method (SM).

Three local loading states and one whole loading state are found in the local loading forming process of representative cross-section. Further, four loading states also exist in local loading forming process of large-sized complicated rib-web components. With the metal distribution in the process, some local loading states may turn into whole loading state. For the representative cross-section, the relative error of metal distribution between SM and FEM results is less than 15 per cent, and the relative error of metal in the rib cavity between SM and FEM results is less than 10 per cent.

Metal flow can be controlled by adjusting the loading states in the process. According to the metal flow laws in different loading states, a simple unequal-thickness billet can be designed to achieve initial metal distribution, and then, the secondary metal distribution can be achieved in the process.