Tool wear evaluations in friction stir processing of commercial titanium Ti–6Al–4V

This research addresses the application of friction stir welding (FWS) of titanium alloy Ti–6Al–4V. Friction stir welding is a recent process, developed in the 1990s for aluminum joining; this joining process is being increasingly applied in many industries from basic materials, such as steel alloys, to high performance alloys, such as titanium. It is a process in great development and has its economic advantages when compared to conventional welding. For high performance alloys such as titanium, a major problem to overcome is the construction of tools that can withstand the extreme process environment. In the literature, the possibilities approached are only few tungsten alloys. Early experiments with tools made of cemented carbide (WC) showed optimistic results consistent with the literature. It was initially thought that WC tools may be an option to the FSW process since it is possible to improve the wear resistance of the tool. The metallographic analysis of the welds did not show primary defects of voids (tunneling) or similar internal defects due to processing, only defects related to tool wear which can cause loss of weld quality. The severe tool wear caused loss of surface quality and inclusions of fragments inside the joining, which should be corrected or mitigated by means of coating techniques on tool, or the replacement of cemented carbide with tungsten alloys, as found in the literature.

Investigation on the effect of cutting fluid pressure on surface quality measurement in high speed thread milling of brass alloy (C3600) and aluminium alloy (5083)

The quality of a machined finish plays a major role in the performance of milling operations, good surface quality can significantly improve fatigue strength, corrosion resistance, or creep behaviour as well as surface friction. In this study, the effect of cutting parameters and cutting fluid pressure on the quality measurement of the surface of the crest for threads milled during high speed milling operations has been scrutinised. Cutting fluid pressure, feed rate and spindle speed were the input parameters whilst minimising surface roughness on the crest of the thread was the target. The experimental study was designed using the Taguchi L32 array. Analysing and modelling the effective parameters were carried out using both a multi-layer perceptron (MLP) and radial basis function (RBF) artificial neural networks (ANNs). These were shown to be highly adept for such tasks. In this paper, the analysis of surface roughness at the crest of the thread in high speed thread milling using a high accuracy optical profile-meter is an original contribution to the literature. The experimental results demonstrated that the surface quality in the crest of the thread was improved by increasing cutting speed, feed rate ranging 0.41-0.45 m/min and cutting fluid pressure ranging 2-3.5 bars. These outcomes characterised the ANN as a promising application for surface profile modelling in precision machining.

Design, characterisation and in vivo testing of a new, adjustable stiffness, external fixator for the rat femur

Very little is known about the infl uence of the mechanical environment on the healing of large segmental defects. This partly reflects the lack of standardised, well characterised technologies to enable such studies. Here we report the design, construction and characterisation of a novel external fixator for use in conjunction with rat femoral defects. This device not only imposes a predetermined axial stiffness on the lesion, but also enables the stiffness to be changed during the healing process. The main frame of the fi xator consists of polyethylethylketone with titanium alloy mounting pins. The stiffness of the fi xator is determined by interchangeable connection elements of different thicknesses. Fixators were shown to stabilise 5 mm femoral defects in rats in vivo for at least 8 weeks during unrestricted cage activity. No distortion or infections, including pin infections, were noted. The healing process was simulated in vitro by inserting into a 5 mm femoral defect, materials whose Young’s moduli approximated those of the different tissues present in regenerating bone. These studies confirmed that, although the external fixator is the major determinant of axial stiffness during the early phase of healing, the regenerate within the lesion subsequently dominates this property. There is much clinical interest in altering the mechanics of the defect to enhance bone healing. Our data suggest that, if alteration of the mechanical environment is to be used to modulate the healing of large segmental defects, this needs to be performed before the tissue properties become dominant.

High temperature deformation processing maps for boron modified Ti-6Al-4V alloys

The alloy, Ti-6Al-4V is an alpha + beta Ti alloy that has large prior beta grain size (similar to 2 mm) in the as cast state. Minor addition of B (about 0.1 wt.%) to it refines the grain size significantly as well as produces in-situ TiB needles. The role played by these microstructural modifications on high temperature deformation processing maps of B-modified Ti64 alloys is examined in this paper.Power dissipation efficiency and instability maps have been generated within the temperature range of 750-1000 degrees C and strain rate range of 10(-3)-10(+1) s(-1). Various deformation mechanisms, which operate in different temperature-strain rate regimes, were identified with the aid of the maps and complementary microstructural analysis of the deformed specimens. Results indicate four distinct deformation domains within the range of experimental conditions examined, with the combination of 900-1000 degrees C and 10(-3)-10(-2) s(-1) being the optimum for hot working. In that zone, dynamic globularization of alpha laths is the principle deformation mechanism. The marked reduction in the prior beta grain size, achieved with the addition of B, does not appear to alter this domain markedly. The other domains, with negative values of instability parameter, show undesirable microstructural features such as extensive kinking/bending of alpha laths and breaking of beta laths for Ti64-0.0B as well as generation of voids and cracks in the matrix and TiB needles in the B-modified alloys. (C) 2010 Elsevier B.V. All rights reserved.

Control of transient thermal response during sequential open-die forging: A trajectory optimization approach

A trajectory optimization approach is applied to the design of a sequence of open-die forging operations in order to control the transient thermal response of a large titanium alloy billet. The amount of time tire billet is soaked in furnace prior to each successive forging operation is optimized to minimize the total process time while simultaneously satisfying constraints on the maximum and minimum values of the billet's temperature distribution to avoid microstructural defects during forging. The results indicate that a "differential" heating profile is the most effective at meeting these design goals.

Avaliação in vitro da variação do torque de remoção de parafusos para fixação de pilares protéticos submetidos a ciclos de parafusamento e desparafusamento

O afrouxamento dos parafusos protéticos é descrito na literatura como uma das complicações mais frequentes das próteses sobre implantes. Durante sua confecção, os profissionais sentem necessidade de remover várias vezes as próteses e/ou componentes protéticos, soltando e re-apertando os parafusos repetidamente. O principal objetivo deste trabalho foi avaliar a variação do torque de remoção de parafusos de fixação de pilares protéticos a implantes osteointegráveis após sucessivos ciclos de parafusamento e desparafusamento. Outro objetivo foi avaliar a influência do hexágono da base do pilar no torque de remoção dos parafusos. Para isso, foram utilizados 20 implantes de plataforma regular com hexágono externo e 20 pilares protéticos sextavados, que foram parafusados aos implantes com um parafuso de titânio, aplicando-se a este um torque de 32Ncm, por meio de um torquímetro digital. Os conjuntos implante/pilar/parafuso foram divididos em dois grupos: (1) pilares cujo hexágono da base foram removidos e (2) pilares convencionais, com hexágono na base. Cada conjunto recebeu uma restauração provisória e foi submetido a ciclagem mecânica por 15 minutos. Depois, os parafusos foram removidos, medindo-se o torque de remoção. Esta sequência foi repetida dez vezes e então o parafuso foi trocado por outro sem uso, e mais um ciclo foi realizado. Uma análise de regressão linear demonstrou nos dois grupos uma queda do torque de remoção do parafuso ao longo dos repetidos ciclos de inserção/remoção. A comparação entre os coeficientes da regressão nos dois grupos não revelou diferença entre eles. Também não houve diferença entre as médias das 5 últimas repetições e o 11 ciclo, com o parafuso novo. Concluiu-se que (1) repetidos parafusamentos e desparafusamentos promoveram a diminuição progressiva do torque de remoção dos parafusos, (2) a troca do parafuso por outro sem uso após dez ciclos de inserção/remoção não aumentou sua resistência ao afrouxamento, e (3) a remoção do hexágono da base do pilar protético não exerceu nenhum efeito sobre o torque de remoção do parafuso.

Comportamento tribocorrosivo do aço inoxidável e de ligas de titânio em meio salino

No presente trabalho, foram realizados ensaios de tribocorrosão no aço inoxidável AISI 304L, no titânio comercialmente puro (CPTi) e na liga de titânio Ti6Al4V em solução aquosa de 0,90% m/v NaCl. Amostras de ligas de titânio com tratamento térmico superficial de refusão a laser também foram utilizadas. Um tribômetro do tipo pino-no-disco com contracorpo de alumina foi usado. Técnicas eletroquímicas in situ de monitoramento em circuito aberto, espectroscopia de impedância eletroquímica, curvas de polarização e amperimetria de resistência nula foram empregadas. Os resultados obtidos indicam que o desgaste tribocorrosivo das ligas de titânio é mais intenso do que o observado no aço inoxidável, apresentando perfis de superfície mais irregulares. A análise da impedância eletroquímica mostrou que todos os materiais utilizados apresentam uma rápida recuperação da camada passiva, exibindo módulos e fases um pouco menores do que os medidos antes do desgaste. Sob atrito, os diagramas de impedância apresentam uma forte redução do módulo. Sob desgaste, o expoente α do elemento de fase constante (CPE) atinge seu valor mais baixo, enquanto o parâmetro γ é máximo. As curvas de polarização exibem potenciais menores e densidades de corrente de corrosão maiores durante o desgaste. O tratamento de refusão a laser, embora mude a microestrutura e a dureza superficial das amostras, não indica uma mudança aparente nos parâmetros eletroquímicos sob tribocorrosão, bem como do coeficiente de atrito. Nos ensaios de amperimetria de resistência nula, foi possível estimar a corrente mensurada no ARN por meio do emprego de um circuito elétrico equivalente. A densidade espectral de potência dos sinais de potencial e de corrente exibe a frequência de rotação (1,25 Hz) e seus harmônicos. Para baixas frequências (abaixo de 10 mHz), o decaimento obedece à relação 1 ⁄ e 1⁄ para os sinais de potencial e corrente, respectivamente.

基于人工神经网络的钛合金焊接接头机械性能预测

采用多层前向反馈神经网络模型,对钛合金钨极氩弧焊的焊接接头机械性能进行了模拟和预测。其中,输入参数包括钛合金成分、冷却速度和热处理参数;输出参数包括5个重要的机械性能,即极限抗拉强度、延伸率、断面收缩率、屈服强度和硬度。详细分析了铝和钒这2种元素对机械性能的影响。

Effect of resonance frequency, power input, and saturation gas type on the oxidation efficiency of an ultrasound horn

The sonochemical oxidation efficiency (eta(ox)) of a commercial titanium alloy ultrasound horn has been measured using potassium iodide as a dosimeter at its main resonance frequency (20 kHz) and two higher resonance frequencies (41 and 62 kHz). Narrow power and frequency ranges have been chosen to minimise secondary effects such as changing bubble stability, and time available for radical diffusion from the bubble to the liquid. The oxidation efficiency, eta(ox), is proportional to the frequency and to the power transmitted to the liquid (275 mL) in the applied power range (1-6 W) under argon. Luminol radical visualisation measurements show that the radical generation rate increases and a redistribution of radical producing zones is achieved at increasing frequency. Argon, helium, air, nitrogen, oxygen, and carbon dioxide have been used as saturation gases in potassium iodide oxidation experiments. The highest eta(ox) has been observed at 5 W under air at 62 kHz. The presence of carbon dioxide in air gives enhanced nucleation at 41 and 62 kHz and has a strong influence on eta(ox). This is supported by the luminol images, the measured dependence of eta(ox). on input power, and bubble images recorded under carbon dioxide. The results give insight into the interplay between saturation gas and frequency, nucleation, and their effect on eta(ox). (C) 2010 Elsevier B.V. All rights reserved.

Effect of contact pressure on fretting fatigue behavior of Ti-1023

With a new test facility, we have investigated fretting fatigue properties of Ti-1023 titanium alloy at different contact pressure. Both fatigue fracture and fretting scar were analyzed by scanning electron microscopy (SEM). Moreover, the depth of crack initiation area in fatigue fracture has been analyzed quantitatively, to investigate the relationship between the depth of crack initiation area and the fretting fatigue strength. The changing trends of the depth of crack initiation area and fretting fatigue strength with the increase of contact pressure show obvious opposite correlations. The depth of crack initiation area increases rapidly with the increase of contact pressure at low contact pressure (smaller than 10 MPa), and the fretting fatigue strength drops rapidly. At the contact pressure of 10–45 MPa, both the depth of crack initiation area and the fretting fatigue strength do not vary significantly. Contact pressure influences fatigue strength through influencing the initiation of fatigue crack. The main damage patterns are fatigue flake and plow.

Estudo da maquinabilidade das ligas Ti-6Al-4V e Co-28Cr-6Mo na fresagem de dispositivos biomédicos

Os estudos de maquinabilidade de biomateriais e outros materiais aplicados na área médica são extensos. Todavia, muitos destes estudos recorrem a modelos de geometria regular e operações elementares de maquinagem. Relativamente a estas, os estudos académicos atualmente disponíveis mostram que a tecnologia preferencial é o torneamento, opção que se fundamenta na simplicidade de análise (corte ortogonal). Saliente-se ainda que, neste contexto, a liga de titânio Ti-6Al-4V constitui o biomaterial mais utilizado. Numa perspetiva complementar, refira-se que as publicações científicas evidenciam que a informação disponível sobre a fresagem Ti-6Al-4V não é muito extensa e a do Co-28Cr-6Mo é quase inexistente. A presente dissertação enquadra-se neste domínio e representa mais uma contribuição para o estudo da maquinabilidade das ligas de Titânio e de crómio-cobalto. A aplicação de operações de maquinagem complexas, através do recurso a programas informáticos de fabrico assistido por computador (CAM), em geometrias complexas, como é o caso das próteses femorais anatómicas, e o estudo comparativo da maquinabilidade das ligas Co-28Cr-6Mo e Ti-6Al-4V, constituem os objetivos fundamentais deste trabalho de doutoramento. Neste trabalho aborda-se a problemática da maquinabilidade das ligas metálicas usadas nos implantes ortopédicos, nomeadamente as ligas de titânio, de crómiocobalto e os aços Inoxidáveis. Efetua-se ainda um estudo da maquinagem de uma prótese femoral com uma forma geométrica complexa, onde as operações de corte foram geradas recorrendo às tecnologias de fabrico assistido por computador (CAD/CAM). Posteriormente, procedeu-se ao estudo da maquinabilidade das duas ligas usadas neste trabalho, dando uma atenção particular à determinação das forças de corte para diferentes velocidades de corte. Para além da monitorização da evolução da força de corte, o desgaste das ferramentas, a dureza e a rugosidade foram avaliadas, em função da velocidade de corte imposta. Por fim, com base nas estratégias de maquinagem adotadas, analisa-se a maquinabilidade e selecionam-se os parâmetros de corte mais favoráveis para as ligas de Titânio e Crómio-cobalto. Os resultados obtidos mostram que a liga de crómio-cobalto induz maior valor de força de corte do que a liga de titânio. Observa-se um aumento progressivo das forças de corte quando a velocidade de corte aumenta, até atingir o valor máximo para a velocidade de corte de 80m/min, após a qual, a força de corte tende a diminuir. Apesar do fabricante das ferramentas recomendar a velocidade de corte de 50 m/min para ambos os materiais, conclui-se que a velocidade de corte de 65 m/min induz o mesmo desgaste na ferramenta de corte no caso da liga de titânio, e menor desgaste no caso da liga de crómio-cobalto.

Natural fiber reinforced composites for femoral component of total hip arthroplasty

This paper describes a theoretical approach to compare two types of fiber reinforced composite materials for femoral component of hip implants. The natural fiber reinforced composite implant is compared with carbon fiber reinforced composite and the results are evaluated against the control solution of a metallic implant made of titanium alloy. With identical geometry and loading condition, the composite implants assumed lower stresses, thus induced more loads to the bone and consequently reduced the risk of stress shielding, whilst the natural fiber reinforced composite showed promising result compared with carbon fibers. However, natural fibers, as well as carbon fibers, lack the power to improve interface debonding due to excessive loads in interface. Nevertheless, natural fiber reinforced composite could be an appropriate alternative given its capability of tailoring and achieving the optimal fiber orientation and robust design.

The martensitic transformation texture in Ti-6Al-4V

The transformation texture associated with martensite formation in the titanium alloy Ti- 6Al-4V has been investigated. Samples were heated into the fully b phase and quenched to form a microstructure of very fine a' martensite with no evidence of diffusional transformation at the prior b grain boundaries. EBSD texture measurements on the martensite showed that within each prior b grain, although typically all 12 variants of a’ were formed, the fractions of variants was far from uniform. The a’ texture was markedly different from values calculated using equal variant probability, also indicating that significant variant selection was occurring during martensitic transformation. This effect was modelled on the basis of elastic interaction between martensite events.