https://docs.lib.purdue.edu/cgi/viewcontent.cgi?article=1037&context=mepubs

Additive manufacturing of Ti6Al4V alloy: A review

An overview of the machinability of aeroengine alloys

Significant advances have been made in understanding the behaviour of engineering materials when machining at higher cutting conditions from practical and theoretical standpoints. This approach has enabled the aerospace industry to cope with constant introduction of new materials that allow the engine temperature to increase at a rate of 10 °C per annum since the 1950s. Improvements achieved from research and development activities in this area have particularly enhanced the machining of difficult-to-cut nickel base and titanium alloys that have traditionally exhibited low machinability due to their peculiar characteristics such as poor thermal conductivity, high strength at elevated temperature, resistance to wear and chemical degradation, etc. A good understanding of the cutting tool materials, cutting conditions, processing time and functionality of the machined component will lead to efficient and economic machining of nickel and titanium base superalloys. This paper presents an overview of major advances in machining techniques that have resulted to step increase in productivity, hence lower manufacturing cost, without adverse effect on the surface finish, surface integrity, circularity and hardness variation of the machined component.

Key improvements in the machining of difficult-to-cut aerospace superalloys

Additive Manufacturing of titanium components holds promise to deliver benefits such as reduced cost, weight and carbon emissions during both manufacture and use. To capitalize on these benefits, it must be shown that the mechanical performance of parts produced by Additive Manufacturing can meet design requirements that are typically based on wrought material performance properties. Of particular concern for safety critical structures are the fatigue properties of parts produced by Additive Manufacturing. This research evaluates the fatigue properties of Ti–6Al–4V specimens produced by the Selective Laser Melting additive manufacturing process. It was found that the fatigue life is significantly lower compared to wrought material. This reduction in fatigue performance was attributed to a variety of issues, such as microstructure, porosity, surface finish and residual stress. There was also found to be a high degree of anisotropy in the fatigue performance associated with the specimen build orientation.

Fatigue performance evaluation of selective laser melted Ti–6Al–4V

There is probably no other material more closely related to aerospace than titanium and its alloys. With a density of 4.5 g/cm{sup 3}, titanium alloys are only about half as heavy as steel or Ni-based superalloys, yielding an excellent strength-to-weight ratio. Furthermore, they have exceptional corrosion resistance. The use of titanium alloys in the aerospace sector will be highlighted including airframe, engine, helicopter, and space applications. (Abstract Copyright [2003], Wiley Periodicals, Inc.)

Titanium Alloys for Aerospace Applications

Titanium and titanium alloys are excellent candidates for aerospace applications owing to their high strength to weight ratio and excellent corrosion resistance. Titanium usage is, however, strongly limited by its higher cost relative to competing materials, primarily aluminum alloys and steels. Hence the advantages of using titanium must be balanced against this added cost. The titanium alloys used for aerospace applications, some of the characteristics of these alloys, the rationale for utilizing them, and some specific applications of different types of actual usage, and constraints, are discussed as an expansion of previous reviews of β alloy applications. [1,2]

An overview on the use of titanium in the aerospace industry

This study has examined the potential for enhancing the fatigue performance of Ti–15V–3Cr–3Al–3Sn sheet through variations in heat treatment and thermomechanical processing procedures. Processing variants included conventional solution treatment and aging, solution treatment with duplex- and triplex-ages, and cold and warm rolling followed by aging. Tensile and smooth fatigue performance of each processing route were evaluated and compared to ‘standard’ commercial practice. These processing avenues provided a wide range of microstructures with tensile strengths ranging from 1070 to 1610 MPa. Enhancements in fatigue performance were dependent on processing and stress level. At high stresses, i.e. within the low cycle regime, a 15% improvement in the maximum stress for a fixed 30 000 cycle lifetime was achieved. At lower stresses, i.e. within the high cycle fatigue ‘limit’ regime, a 50% improvement relative to the standard heat treatment was achieved. A good correlation of fatigue and tensile strengths was observed; generally, the smooth fatigue properties improved as the tensile strength increased.

The influence of thermomechanical processing on the smooth fatigue properties of Ti–15V–3Cr–3Al–3Sn

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An overview on the use of titanium in the aerospace industry

The influence of thermomechanical processing on the smooth fatigue properties of Ti–15V–3Cr–3Al–3Sn