Rough turning of titanium alloy (6Al-4V)

Metal machining is the complex process due the used cutting parameters. In metal cutting process, materials of workpiece differ widely in their ability to deform plastically, to fracture and to sustain tensile stresses. Moreover, the material involved in the process has a great influence in these operations. The Ti-6Al-4V alloy is very used in the aeronautical industry, mainly in the manufacture of engines, has very important properties such the mechanical and corrosion resistance in high te mperatures. The turning of the Ti-Al-4V alloy is very difficult due the rapid tool wear. Such behavior result of the its low thermal conductivity in addition the high reactivity with the cutting tool. The formed chip is segmented and regions of the large deformation named shear bands plows formed. The machinability of the cutting process can be evaluated by several measures including power consume, machined surface quality, tool wear, tool life, microstructure and morphology of the obtained chip. This paper studies the effect of cutting parameters, speed and feed rates, in the tool wear and chip properties using uncoating cemented carbide tool. Microe-structural characterization of the chip and tool wear was performed using scanning electron microscopy (SEM) and Light Optical Mcroscopy (LOM).

One-hit machining of titanium alloy (Ti-6al-4v) wall component with trochoidal milling

This research will definitely give guidelines to industries associated with titanium slot machining.

Analysis on turning Ti-6Al-4V with different cooling methods

The aim of this paper is to optimize the machining of Ti-6Al-4V alloy, by studying the chip formation, roughness and tool wear for different cooling conditions. The results were compared between cooling methods, minimal quantity of fluid (MQF) and flooding, and also without fluid for the tool H13A. The turning of Ti-6Al-4V has shown good results on roughness (0, 8μm) and tool life, which was 11% lower with MQF than with the flooding method. The tool wear causes variation of the shear angle, which promotes strength hardening of the chip. As a result, the machined surface could be damaged. The use of the cutting fluid helps to save the cutting edge and could reduce the strength hardening. Nevertheless, it could also facilitate the formation of built-up edge. The nucleation of alpha lamellar colonies can occur due to a combination of deformation rates and temperature, mainly when the flooding is used, but it's not conclusive. The lamellar colonies were also found with the MQF in some regions, however, this structure did not show hardness variation compared to equiaxial. For all this reasons, the machining parameters might be carefully chosen.

Characterization of a new beta titanium alloy, Ti-12Mo-3Nb, for biomedical applications

In recent years, different beta titanium alloys have been developed for biomedical applications with a combination of mechanical properties including a low Young's modulus, high strength, fatigue resistance and good ductility with excellent corrosion resistance. From this perspective, a new metastable beta titanium Ti-12Mo-3Nb alloy was developed with the replacement of both vanadium and aluminum from the traditional Ti-6Al-4V alloy. This paper presents the microstructure, mechanical properties and corrosion resistance of the Ti-12Mo-3Nb alloy heat-treated at 950 degrees C for 1 h. The material was characterized by X-ray diffraction and by scanning electron microscopy. Tensile tests were carried out at room temperature. Corrosion tests were performed using Ringer's solution at 25 degrees C. The results showed that this alloy could potentially be used for biomedical purposes due to its good mechanical properties and spontaneous passivation. (c) 2011 Elsevier B.V. All rights reserved.

Metallurgical and machinability characteristics of wrought and selective laser melted Ti-6Al-4V

This research work presents a machinability study between wrought grade titanium and selective laser melted (SLM) titanium Ti-6Al-4V in a face turning operation, machined at cutting speeds between 60 and 180 m/min. Machinability characteristics such as tool wear, cutting forces, and machined surface quality were investigated. Coating delamination, adhesion, abrasion, attrition, and chipping wear mechanisms were dominant during machining of SLM Ti-6Al-4V. Maximum flank wear was found higher in machining SLM Ti-6Al-4V compared to wrought Ti-6Al-4V at all speeds. It was also found that high machining speeds lead to catastrophic failure of the cutting tool during machining of SLM Ti-6Al-4V. Cutting force was higher in machining SLM Ti-6Al-4V as compared to wrought Ti-6Al-4V for all cutting speeds due to its higher strength and hardness. Surface finish improved with the cutting speed despite the high tool wear observed at high machining speeds. Overall, machinability of SLM Ti-6Al-4V was found poor as compared to the wrought alloy.

Texture Evolution in Boron Modified Ti-6Al-4V Alloy

Owing to their high strength-to-weight ratio, excellent mechanical properties and corrosion resistance, titanium (Ti) and its alloys, especially (alpha+beta) alloys like Ti-6Al-4V is the backbone materials for aerospace, energy, and chemical industries. Trace boron addition (similar to 0.1 wt. %) to the alloy Ti-6Al-4V produces a reduction in as-cast grain size by roughly an order of magnitude resulting in enhanced ductility, higher stiffness, strength and good fracture resistance. Boron addition could also affect the evolution of texture and microstructure in the material. The solidification microstructures of Boron free as well as Boron containing Ti-6Al-4V are found to be almost homogeneous from periphery towards the center of as-cast ingot in terms of both alpha-colony size and distribution. Boron addition substantially reduces alpha-colony size (similar to 50-80 mu m). A gradual change in alpha texture from periphery towards the center has been observed with orientations close to specific texture components suggesting the formation of texture zones. The mechanism of texture evolution can be visualized as a result of variant selection during solidification through (alpha+beta) phase field.

Fretting wear behaviour of hydroxyapatite-titanium composites in simulated body fluid, supplemented with 5 g l(-1) bovine serum albumin

Damaged articulating joints can be repaired or replaced with synthetic biomaterials, which can release wear debris due to articulation, leading to the osteolysis. In a recent work, it has been shown that it is possible to achieve a better combination of flexural strength/fracture toughness as well as in vitro bioactivity and cytocompatibility properties in spark plasma sintered hydroxyapatite-titanium (HA-Ti) composites. Although hydroxyapatite and titanium are well documented for their good biocompatibility, nanosized hydroxyapatite (HA) and titanium (Ti) particles can cause severe toxicity to cells. In order to address this issue, fretting wear study of HA-Ti composites under dry and wet (1x SBF, supplemented with 5 g l(-1) bovine serum albumin (BSA)) condition was performed to assess the wear resistance as well as wear debris formation, in vitro. The experimental results reveal one order of magnitude lower wear rate for HA-10 wt% Ti (7.5 x 10(-5) mm(3) N-1 m(-1)) composite than monolithic HA (3.9 x 10(-4) mm(3) N-1 m(-1)) in simulated body fluid. The difference in the tribological properties has been analyzed in the light of phase assemblages and mechanical properties. Overall, the results suggest the potential use of HA-Ti composites over existing HA-based biocomposites in orthopedic as well as dental applications.

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.

Bone Formation Following Implantation of Titanium Sponge Rods into Humeral Osteotomies in Dogs: A Histological and Histometrical Study

Background: Titanium (Ti) is widely proven to enhance bone contact and growth on its surface. It is expected that bone defects could benefit from Ti to promote healing and to increase strength of the implanted area. Purpose: The present study aimed at comparing the potential of porous Ti sponge rods with synthetic hydroxyapatite (HA) for the healing of bone defects in a canine model. Material and Methods: Six mongrel dogs were submitted to three trephined osteotomies of 6.0 x 4.0 mm in one humerus and after 2 months another three osteotomies were performed in the contralateral humerus. A total of 36 defects were randomly filled either with Ti foam, particulate HA, or coagulum (control). The six animals were killed 4 months after the first surgery for histological and histometrical analysis. Results: The Ti-foam surface was frequently found in intimate contact with new bone especially at the defect walls. Control sites showed higher amounts of newly formed bone at 2 months - Ti (p = 0.000) and HA (p = 0.009) - and 4 months when compared with Ti (p = 0.001). Differently from HA, the Ti foam was densely distributed across the defect area which rendered less space for bone growth in the latter`s sites. The use of Ti foams or HA resulted in similar amounts of bone formation in both time intervals. Nevertheless, the presence of a Ti-foam rod preserved defect`s marginal bone height as compared with control groups. Also, the Ti-foam group showed a more mature bone pattern at 4 months than HA sites. Conclusion: The Ti foam exhibited good biocompatibility, and its application resulted in improved maintenance of bone height compared with control sites. The Ti foam in a rod design exhibited bone ingrowth properties suitable for further exploration in other experimental situations.

Apatite-inducing ability of titanium oxide layer on titanium surface : the effect of surface energy

In the present study, pure titanium (Ti) plates were firstly treated to form various types of oxide layers on the surface and then were immersed into simulated body fluid (SBF) to evaluate the apatite-forming ability. The surface morphology and roughness of the different oxide layers were measured by atomic force microscopy (AFM), and the surface energies were determined based on the Owens–Wendt (OW) methods. It was found that Ti samples after alkali heat (AH) treatment achieved the best apatite formation after soaking in SBF for three weeks, compared with those without treatment, thermal or H₂O₂ oxidation. Furthermore, contact angle measurement revealed that the oxide layer on the alkali heat treated Ti samples possessed the highest surface energy. The results indicate that the apatite-inducing ability of a titanium oxide layer links to its surface energy. Apatite nucleation is easier on a surface with a higher surface energy.

Effect of surface roughness of Ti, Zr, and TiZr on apatite precipitation from simulated body fluid

Some of the critical properties for a successful orthopedic or dental implant material are its biocompatibility and bioactivity. Pure titanium (Ti) and zirconium (Zr) are widely accepted as biocompatible metals, due to their non-toxicity. While the bioactivity of Ti and some Ti alloys has been extensively investigated, there is still insufficient data for Zr and titanium-zirconium (TiZr) alloys. In the present study, the bioactivity, that is, the apatite forming ability on the alkali and heat treated surfaces of Ti, Zr, and TiZr alloy in simulated body fluid (SBF), was studied. In particular, the effect of the surface roughness characteristics on the bioactivity was evaluated for the first time. The results indicate that the pretreated Ti, Zr and TiZr alloy could form apatite coating on their surfaces. It should be noted that the surface roughness also critically affected the bioactivity of these pretreated metallic samples. A surface morphology with an average roughness of approximately 0.6 microm led to the fastest apatite formation on the metal surfaces. This apatite layer on the metal surface is expected to bond to the surrounding bones directly after implantation.

Simulation of three-point bending test of titanium foam for biomedical applications

Using Titanium (Ti) foam as an implant material is a new approach for biomedical applications and it is important to understand the mechanical behaviors of this new foam material. In the present study, the bending of the Ti foam has been simulated and compared against recently published data [1]. FE Analysis has been performed by Abaqus software. Stiffness and Yield strength of foams between 50% (cortical bone) to 80% (cancellous bone) porosity range were considered. This study showed that crushable foam material model in Abaqus, which has developed primarily for Aluminum (Al) foam alloys, is also valid for Ti Foam before any crack or damage occurs in the sample.

Effect of heat-treatment atmosphere on the bond strength of apatite layer on Ti substrate

Objectives
The purpose of this study was to investigate the bond strength of apatite layer on titanium (Ti) substrate coated by biomimetic method and to improve the bonding of apatite layer to Ti substrate by optimizing the alkali heat-treatment process.

Methods
Ti plates pre-treated with an alkali solution of 10 M sodium hydroxide (NaOH) were heat-treated at 600 °C for 1 h at different atmospheres: in air and in vacuum. A dense apatite layer formed on top of the sodium titanate layer after soaking the alkali and heat-treated Ti samples in simulated body fluid (SBF) for up to 3 weeks. The bond strengths of the sodium titanate layer on Ti substrate, and apatite layer on the sodium titanate layer, were measured, respectively, by applying a tensile load. The fracture sites were observed with a scanning electron microscope (SEM).

Results
The apatite layer on the substrate after alkali heat-treatment in air achieved higher bond strength than that on the substrate after alkali heat-treatment in vacuum. It was found that the interfacial structure between the sodium titanate and Ti substrate has a significant influence on the bond strength of the apatite layer.

Significance
It is advised that titanium implants can achieve better osseointegration under load-bearing conditions by depositing an apatite layer in vivo on a Ti surface subjected to alkali and heat-treated in air.