Abstract
Titanium aluminides have become the preferred titanium-based alloys for high temperature applications due to their resistance to oxidation at elevated temperatures. However, the inherent limitations of the conventional methods of manufacturing have adverse effects on the mechanical properties of the alloy and limit its applications. The current study focused on determining the optimum process parameters that could be used to produce a Ti6Al alloy with required microstructural properties and complex geometrical configurations using the direct metal laser sintering method. Single tracks were produced at laser powers of 150 W and 350 W over a wide range of scanning speeds. Continuous tracks were achieved only at a laser power of 150 W at corresponding scanning speeds of 1.0 m/s to 1.4 m/s. A cross sectional analysis was conducted on the single tracks and 1.2 m/s emerged as the optimum scanning speed. 3D objects were manufactured at optimum process parameters of 150 W, 1.2 m/s and a hatch distance of 80 µm. The microstructure of the 3D objects was homogenous which attests that the direct metal laser sintering method could be used to produce Ti6Al parts with the desired mechanical properties and geometrical complexity.
Highlights
Titaniu m has been the preferred metal of choice for many engineering applications due to its outstanding specific strength, corrosion resistance and strength at high temperatures [1]
The geometrical characteristics of the single tracks have a decisive effect on the mechanical propert ies and surface morphology of Direct metal laser sintering (DM LS) built parts [9]
The characteristics of the molten pool are governed by the principal process parameters and the powder layer thickness
Summary
Titaniu m has been the preferred metal of choice for many engineering applications due to its outstanding specific strength, corrosion resistance and strength at high temperatures [1]. Titaniu m alu min ide (TiAl) alloys have been proven to overcome the oxidation disadvantage which has provoked intense academic and industrial research into developing TiAl-based alloys for high temperature engineering applications. TiA l based alloys have a strong potential to increase the thrust-to-weight ratio in an aircra ft engine [3]. These alloys could reduce the structural weight of high-performance gas turbine engines by 20– 30%, wh ich wou ld enhance engine performance and fuel efficiency and potentially be a replacement of Ni-based superalloys that are nearly twice as dense (heavy) as TiAl-based alloys [4]
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