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Current methods for the preparation of composite powder feedstock for selective laser melting (SLM) rely on costly nanoparticles or yield inconsistent powder morphology. This study aims to develop a cost-effective Ti6Al4V-carbon feedstock, which preserves the parent Ti6Al4V particle’s flowability, and produces in situ TiC-reinforced Ti6Al4V composites with superior traits.

Ti6Al4V particles were directly mixed with graphite flakes in a planetary ball mill. This composite powder feedstock was used to manufacture in situ TiC-Ti6Al4V composites using various energy densities. Relative porosity, microstructure and hardness of the composites were evaluated for different SLM processing parameters.

Homogeneously carbon-coated Ti6Al4V particles were produced by direct mixing. After SLM processing, in situ grown 100–500 nm size TiC nanoparticles were distributed within the α-martensite Ti6Al4V matrix. The formation of TiC particles refines the Ti6Al4V β grain size. Relative density varied between 96.4% and 99.5% depending on the processing parameters. Hatch distance, exposure time and point distance were all effective on relative porosity change, whereas only exposure time and point distance were effective on hardness change.

This work introduces a novel, cost-effective powder feedstock preparation method for SLM manufacture of Ti6Al4V-TiC composites. The in situ SLM composites achieved in this study have high relative density values, well-dispersed TiC nanoparticles and increased hardness. In addition, the feedstock preparation method can be readily adapted for various matrix and reinforcement materials in future studies.

Titanium alloys and composites have proven to contain desirable properties for use at elevated temperatures. One such material is the Ti750 composite, which can be used at temperatures up to 750°C for a brief period. This paper aims the microstructure, phase compositions, apparent porosity and hardness of both sintered and heat-treated TiC reinforced Ti750 composites for consideration in aircraft engine design.

The fabrication of TiC-reinforced Ti750 composites was achieved through spark plasma sintering (SPS). To analyze the microstructure and X-ray diffraction, a scanning electron microscope (SEM) with model number S-3400N and a D8 advance model machine were used, respectively. The microhardness of the samples was measured using a Vickers hardness tester with model HV-1000. The research incorporated three solid solution treatments: 975°C/3 h/AC, 1,010°C/3 h/AC and 1,025°C/3 h/AC, along with a solid-solution aging treatment at 1,010°C/3 h/AC + 750°C/8 h/AC. Additionally, oxidation analysis was conducted on the samples.

The microstructures contained enhanced TiC and Ti5Si3 phases in the near a-Ti matrix. The microhardness of the sintered composite was over twice that of the matrix alloy, and its porosity was reduced by about 0.35%. The sample treated at 1,010°C/3 h/AC had the highest enhanced peaks and microhardness of 1,277.1 HV. After oxidation at 800°C for 100 h, the accumulated weight of the solid solution composite at 1,010 °C/3 h/AC was the lowest (3.0 mg.cm^-2). The surface microstructure contained oxides of TiO2 and a spalling white area containing a small amount of Al₂O₃ and SiO₂.

There is limited research on Ti-Al-Sn-Zr-Mo-Si-based TMCs using a combination of the SPS method. This study used SiCp as a reinforcement for the Ti750 matrix alloy. The consolidation of SiCp and Ti750 powders using the SPS method, heat treatment of the resulting TiC reinforced Ti750 composites and study of the microstructure and properties of the composites are not found in literature or under consideration for publication in any media.

The purpose of this paper is to investigate tensile properties of TiC particle-reinforced titanium matrix composites (PRTMC) using the elasto-plastic finite element (FE) programs and the homogenization method and the fixed point iteration method.

Two quasi-static and dynamic transient programs of elasto-plastic FE were coded by using FORTRAN. Based on the FE programs, the FE model of the TiC PRTMC with typical microstructures was established by using the fixed point iteration method and the homogenization theory. The hot deformation behavior of TiC PRTMC under different temperatures were analyzed by using the above model and programs.

Calculation results are presented to investigate the influence of different temperatures on the hot deformation behavior of TiC PRTMC. Based on the experimental data, a good agreement was obtained between the numerical predictions and the experimental results, and the feasibility of this method was verified.

The work is original and findings are new, which demonstrates this FE frame combined with the homogenization method and the fixed point iteration method can be used to investigate the tensile behavior of particle-reinforced metal matrix composites.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming, powder metallurgy and composite material processing are briefly discussed. The range of applications of finite elements on these subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE researchers/users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for 1994‐1996, where 1,370 references are listed. This bibliography is an updating of the paper written by Brannberg and Mackerle which has been published in Engineering Computations, Vol. 11 No. 5, 1994, pp. 413‐55.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

Details the development of composites, in particular carbon fibre reinforced plastics, for use in aerospace structures. Describes a wide range of products manufactured by various companies. Looks at the integrity of these materials and the testing methods used to ensure this. In particular, discusses metal matrix composites, aluminium/silicon carbide particulate MMCs and fibre‐metal laminates. Finally looks at advanced composites’ promise of being able to meet the needs of high specific properties and enhanced temperature capability required for future engines.

Copper matrix composites are widely used in high-voltage switches, electrified railways and other electric friction fields. The purpose of this study is to improve its wear resistance and investigate the effect of hybrid carbon nanotubes (CNTs) and titanium diboride (TiB₂) particles reinforced copper matrix composites on electrical wear performance.

CNTs and TiB₂ particles were introduced into copper matrix simultaneously by powder metallurgy combined with electroless copper plating. Electrical wear performance of the composites was studied on self-made pin on disk electrical wear tester.

The results show that the friction coefficient and wear rate of (1CNTs–4TiB₂)/Cu composite are respectively reduced by 40% and 25.3%, compared with single TiB₂/Cu composites. The micron-sized TiB₂ particles can hinder the plastic deformation of composites, and bear part of the load to weaken the wear rate of composites. CNTs with the self-lubricating property can form lubricating layer to reduce the friction coefficient of composites.

This work can provide a design method for further improving the wear properties of TiB₂/Cu composites.

This paper aims to present a broad review of near-a titanium alloys for high-temperature applications.

Following a brief introduction of titanium (Ti) alloys, this paper considers the near-α group of Ti alloys, which are the most popular high-temperature Ti alloys developed for a high-temperature application, particularly in compressor disc and blades in aero-engines. The paper is relied on literature within the past decade to discuss phase stability and microstructural effect of alloying elements, plastic deformation and reinforcements used in the development of these alloys.

The near-a Ti alloys show high potential for high-temperature applications, and many researchers have explored the incorporation of TiC, TiB SiC, Y₂O₃, La₂O₃ and Al₂O₃ reinforcements for improved mechanical properties. Rolling, extrusion, forging and some severe plastic deformation (SPD) techniques, as well as heat treatment methods, have also been explored extensively. There is, however, a paucity of information on SiC, Y₂O₃ and carbon nanotube reinforcements and their combinations for improved mechanical properties. Information on some SPD techniques such as cyclic extrusion compression, multiaxial compression/forging and repeated corrugation and straightening for this class of alloys is also limited.

This paper provides a topical, technical insight into developments in near-a Ti alloys using literature from within the past decade. It also outlines the future developments of this class of Ti alloys.

The purpose of this paper is to identify if the implementation of ultrasonic vibration in laser engineered net shaping (LENS) process can help to reduce internal weaknesses such as porosity, coarse primary TiB whisker and heterogeneous distribution of TiB reinforcement in the LENS-fabricated TiB reinforced Ti matrix composites (TiB-TMC) parts.

An experimental investigation is performed to achieve the results for comparative studies under different fabrication conditions through quantitative data analysis. An approach of microstructural characterization and mechanical testing is conducted to obtain the output attributes. In addition, the theoretical analysis of the physics of ultrasonic vibration in the melting materials is presented to explain the influences of ultrasonic vibration on the microstructural evolution occurred in the part fabrication.

Because of the nonlinear effects of acoustic streaming and cavitation induced by ultrasonic vibration, porosity is significantly reduced and a relatively small variation of pore sizes is achieved. Ultrasonic vibration also causes the formation of smaller TiB whiskers that distribute along grain boundaries with a homogeneous dispersion. Additionally, a quasi-continuous network (QCN) microstructure is considerably finer than that produced by LENS process without ultrasonic vibration. The refinements of both reinforcing TiB whiskers and QCN microstructural grains further improve the microhardness of TiB-TMC parts.

The novel ultrasonic vibration-assisted (UV-A) LENS process of TiB-TMC is conducted in this work for the first time to improve the process performance and part quality.

Organized by the Institute of Materials, this latest MMC conference was subtitled “Design and Innovation” and attracted delegates from research bodies, universities and industry. It enabled exchanges of information on these materials to be made and provided a view of the latest work being undertaken, as well as prospects for the future. The problems associated with the production of MMCs, as well as their potential, were explored, with a range of applications envisaged. As far as their possible use in aerospace is concerned, this is currently limited in scope, but developments and extensive testing will enable the necessary qualification criteria to be established and lead to a variety of uses.