Fibre laser joining of highly dissimilar materials: Commercially pure Ti and PET hybrid joint for medical device applications

Laser transmission joining (LTJ) is growing in importance, and has the potential to become a niche technique for the fabrication of hybrid plastic-metal joints for medical device applications. The possibility of directly joining plastics to metals by LTJ has been demonstrated by a number of recent studies. However, a reliable and quantitative method for defining the contact area between the plastic and metal, facilitating calculation of the mechanical shear stress of the hybrid joints, is still lacking. A new method, based on image analysis using ImageJ, is proposed here to quantify the contact area at the joint interface. The effect of discolouration on the mechanical performance of the hybrid joints is also reported for the first time. Biocompatible polyethylene terephthalate (PET) and commercially pure titanium (Ti) were selected as materials for laser joining using a 200 W CW fibre laser system. The effect of laser power, scanning speed and stand-off distance between the nozzle tip and top surface of the plastic were studied and analysed by Taguchi L9 orthogonal array and ANOVA respectively. The surface morphology, structure and elemental composition on the PET and Ti surfaces after shearing/peeling apart were characterized by SEM, EDX, XRD and XPS.

Effects of plastic coating on K-alpha yield from ultra-short pulse

A study of the K-alpha radiation emitted from Ti foils irradiated with intense, similar to0.2 J, 67 fs, 800 nm laser pulses, scanning a range of intensities (similar to10(15)-10(18) W cm(-2)), is reported. The brightness of single-shot K-alpha line emission from the front of the targets is recorded. The yield from bare titanium (Ti) is compared to that from plastic (parylene-E) coated Ti. It is demonstrated that, for a defocused beam, a thin layer of plastic increases the yield.

Deformation of titanium alloy Ti-6Al-4V under dynamic compression

Deformation localisation is the main reason for material failure in cold forging of titanium alloys and is thus closely related to the production yield of cold forging. In the study of the influence of process parameters on dynamic compression, considering material constitutive behaviour, physical parameters and process parameters, a numerical dynamic compression model for titanium alloys has been constructed. By adjusting the process parameters, the severity of strain localisation and stress state in the localised zone can be controlled thus enhancing the compression performance of titanium alloys.

Effect of microstructure on the fatigue properties of Ti-6Al-4V titanium alloys

Through an analysis on microstructure and high cycle fatigue (HCF) properties of Ti-6Al-4V alloys which were selected from literature, the effects of microstructure types and microstructure parameters on HCF properties were investigated systematically. The results show that the HCF properties are strongly determined by microstructure types for Ti-6Al-4V. Generally the HCF strengths of different microstructures decrease in the order of bimodal, lamellar and equiaxed microstructure. Additionally, microstructure parameters such as the primary a (a) content and the a grain size in bimodal microstructures, the a lamellar width in lamellar microstructure and the a grain size in equiaxed microstructures, can influence the HCF properties. © 2012 Elsevier Ltd.

Effect of fretting on fatigue performance of Ti-1023 titanium alloy

The plain fatigue and fretting fatigue tests of Ti-1023 titanium alloy were performed using a high-frequency push-pull fatigue testing machine. Both σmax versus number of cycles to failure curves were obtained for comparative analysis of the fretting effect on fatigue performance of the titanium alloy. Meanwhile, by analyzing the fracture of plain fatigue and fretting fatigue, the fretting scar and the fretting debris observed by scanning electron microscopy (SEM), the mechanism of fretting fatigue failure of Ti-1023 titanium alloy is discussed. The fretting fatigue strength of Ti-1023 titanium alloy is 175 MPa under 10 MPa contact pressure, which is 21% of plain fatigue strength (836 MPa). Under fretting condition, the Ti-1023 titanium alloy fatigue fracture failure occurs in a shorter fatigue life. When it comes to σmax versus number of cycles to failure curves, data points in the range of 106–107 cycles under plain fatigue condition moved to the range of 105–106 under fretting fatigue condition. The integrity of the fatigue specimen surface was seriously damaged under the effect of fretting. With the alternating stress loaded on specimen, the stress concentrated on the surface of fretting area, which brought earlier the initiation and propagation of crack.

Microstructure and high cycle fatigue fracture surface of a Ti-5Al-5Mo-5V-1Cr-1Fe titanium alloy

Because of the requirements for the damage tolerance and fatigue life of commercial aircraft components, the high cycle fatigue (HCF) properties of Ti–5Al–5Mo–5V–1Cr–1Fe titanium alloy forgings are important. The effects of microstructure types of the α+β titanium alloy on fatigue properties need to be understood. In this paper, by analysing the fracture surfaces of the titanium alloy having four types of microstructure, the effects of microstructure are investigated. The differences of initiation areas and crack propagation among different microstructures were studied. It was found that the area of the initiation region decreases in the order of coarse basketweave, fine basketweave, Widmanstätten, and bimodal microstructure.

3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

As an emerging hole-machining methodology, helical milling process has become increasingly popular in aeromaterials manufacturing research, especially in areas of aircraft structural parts, dies, and molds manufacturing. Helical milling process is highly demanding due to its complex tool geometry and the progressive material failure on the workpiece. This paper outlines the development of a 3D finite element model for helical milling hole of titanium alloy Ti-6Al-4V using commercial FE code ABAQUS/Explicit. The proposed model simulates the helical milling hole process by taking into account the damage initiation and evolution in the workpiece material. A contact model at the interface between end-mill bit and workpiece has been established and the process parameters specified. Furthermore, a simulation procedure is proposed to simulate different cutting processes with the same failure parameters. With this finite element model, a series of FEAs for machined titanium alloy have been carried out and results compared with laboratory experimental data. The effects of machining parameters on helical milling have been elucidated, and the capability and advantage of FE simulation on helical milling process have been well presented.

Differential Scanning Calorimetry Study and Computer Modeling of b a Phase Transformation in Ti-6Al-4V Alloy

The relationship between heat-treatment parameters and microstructure in titanium alloys has so far been mainly studied empirically, using characterization techniques such as microscopy. Calculation and modeling of the kinetics of phase transformation have not yet been widely used for these alloys. Differential scanning calorimetry (DSC) has been widely used for the study of a variety of phase transformations. There has been much work done on the calculation and modeling of the kinetics of phase transformations for different systems based on the results from DSC study. In the present work, the kinetics of the transformation in a Ti-6Al-4V titanium alloy were studied using DSC, at continuous cooling conditions with constant cooling rates of 5 °C, 10 °C, 20 °C, 30 °C, 40 °C, and 50 °C/min. The results from calorimetry were then used to trace and model the transformation kinetics in continuous cooling conditions. Based on suitably interpreted DSC results, continuous cooling–transformation (CCT) diagrams were calculated with lines of isotransformed fraction. The kinetics of transformation were modeled using the Johnson–Mehl–Avrami (JMA) theory and by applying the "concept of additivity." The JMA kinetic parameters were derived. Good agreement between the calculated and experimental transformed fractions is demonstrated. Using the derived kinetic parameters, the transformation in a Ti-6Al-4V alloy can be described for any cooling path and condition. An interpretation of the results from the point of view of activation energy for nucleation is also presented.

Synchrotron X-ray diffraction study of the phase transformations in titanium alloys

High-resolution synchrotron X-ray diffraction was used to study the phase transformations in titanium alloys. Three titanium alloys were investigated: Ti-6Al-4V, Ti-6Al-2Sn-4Zr-2Mo-0.08Si and beta21s. Both room and high temperature measurements were performed. The room temperature experiments were performed to study the structure of the alloys after different heat treatments, namely as received (AR), furnace cooling (FC), water quenching (WQ) and water quenching followed by ageing. The alpha, alpha', alpha'' and beta phases were observed in different combinations depending on the heat treatment conditions and the alloy studied. A multicomponent hexagonal close packed (hcp) alpha phase, with different c and the same a lattice parameters, was detected in Ti-6Al-4V after FC. High temperature synchrotron X-ray diffraction was used for 'in situ' study of the transformations on the sample surface at elevated temperatures. The results were used to trace the kinetics of surface oxidation and the concurrent phase transformations taking place under different conditions. The influence of the temperature and oxygen content on the lattice parameters of the alpha phase was derived and new data obtained on the coefficients of thermal expansion in the different directions of the hcp alpha phase, for Ti-6Al-4V and Ti-6Al-2Sn-4Zr-2Mo-0.08Si.

Dielectronic recombination in He-like titanium ions

Dielectronic recombination (DR) has been studied in highly charged He-like Ti ions using an electron beam ion trap. X-rays emitted from radiative recombination (RR) and DR were observed as the electron beam energy was scanned through the resonances. Differential DR resonant strengths were determined by normalizing the DR x-ray intensity to the RR intensity using theoretical RR cross sections. KLn (2 less than or equal to n less than or equal to 5) resonant strengths were determined for He-like Ti ions. The differential resonant strengths were calibrated without reference to any theoretical DR calculations while the electron energy scale was derived with reference to the well-known energy for ionization of the He-like and H-like ions from the ground state. Calibration in this way facilitates a more exacting comparison between theory and experiment than has been reported previously. To facilitate this comparison, total and differential theoretical resonance strengths were calculated. These calculations were found to be in good agreement with the measured results.

Stabilization of Ti-molecular sieve catalysts used in selective sulfoxidation reactions by ionic liquids

Sulfoxidation reactions of 4,6-dimethyl-2-methylthiopyrimidine have been performed using titanosilicate catalysts in ionic liquids, dioxane and ethanol. The ionic liquid reactions showed superior reactivity compared with molecular solvents. Moreover, on examination of the recycling of the catalyst, a significant increase in the stability of catalyst was found both in terms of recycling activity and leaching of the titanium from the catalyst. The mechanism by which the ionic liquid reduces the solubilisation of the catalysts is explored.

Relationship between microstructure and deformation behaviour during dynamic compression in Ti-3Al-5Mo-5V alloy

The relationship between microstructure and deformation and damage behaviour during dynamic compression in Ti-3Al-5Mo-5V alloy has been studied using several experimental techniques, including optical microscopy, scanning electron microscopy and microhardness measurements. It was found that the deformation behaviour during dynamic compression was closely related to deformation parameters. After dynamic deformation, the deformation shear band that formed in the titanium alloy had microhardness similar to that of the matrix. However, the microhardness of the white shear band was much higher than the matrix microhardness. The effects of deformation parameters, including deformation rate and deformation degree, on deformation localisation were investigated. Based on the results from the present work, the microstructure and deformation processing parameters can be optimised. In addition, treatment methods after dynamic compression were explored to restore alloy properties. Using post-deformation heat treatment, the microstructure and property inhomogeneity caused by shear bands could be largely removed.