Titanium Aluminum Alloy Research Articles

Modeling and Machine Learning of Vibration Amplitude and Surface Roughness after Waterjet Cutting.

This study focused on analyzing vibrations during waterjet cutting with variable technological parameters (speed, vfi; and pressure, pi), using a three-axis accelerometer from SEQUOIA for three different materials: aluminum alloy, titanium alloy, and steel. Difficult-to-machine materials often require specialized tools and machinery for machining; however, waterjet cutting offers an alternative. Vibrations during this process can affect the quality of cutting edges and surfaces. Surface roughness was measured by contact methods after waterjet cutting. A machine learning (ML) model was developed using the obtained maximum acceleration values and surface roughness parameters (Ra, Rz, and RSm). In this study, five different models were adopted. Due to the characteristics of the data, five regression methods were selected: Random Forest Regressor, Linear Regression, Gradient Boosting Regressor, LGBM Regressor, and XGBRF Regressor. The maximum vibration amplitude reached the lowest acceleration value for aluminum alloy (not exceeding 5 m/s2), indicating its susceptibility to cutting while maintaining a high surface quality. However, significantly higher acceleration amplitudes (up to 60 m/s2) were registered for steel and titanium alloy in all process zones. The predicted roughness parameters were determined from the developed models using second-degree regression equations. The prediction of vibration parameters and surface quality estimators after waterjet cutting can be a useful tool that for allows for the selection of the optimal abrasive waterjet machining (AWJM) technological parameters.

Investigations on the diffusion bonding of titanium alloy and aluminum alloy using copper at low bonding pressure

This research investigates the diffusion bonding of hybrid aluminum (Al)–titanium (Ti) joints using a copper (Cu) interlayer in a vacuum environment. At 610 °C and 1 MPa pressure, partial melting of Al caused deformation and misalignment, while 520 °C showed no melting of Al–Cu at the interface. A rod-shaped precipitate with primarily Al was observed at 550 °C, and grain coarsening occurred at 580 °C at the interface, accompanied by increased Cu diffusion within the Al matrix for a bonding time of 45 min. A Ti–Al-based intermetallic layer formed on the Ti side, but voids and cracks were present in the Al–Cu diffusion region at 580 °C. Hardness variation resulted from microstructural changes due to bonding temperature, particularly near the bond line due to hard intermetallic compounds. Shear strength averaged 41 MPa at 550 °C and decreased to 33 MPa at 580 °C due to grain growth, voids, and crack propagation, causing brittle joint failure at the interface. X-ray diffraction on the fracture surfaces revealed that the failure of diffusion-bonded joints is attributed to fractures through the Ti–Al-based intermetallic compounds at the interface and unbonded region.

Microstructure and Mechanical Properties Investigations of Pure Titanium-Aluminum Alloy Composite Fabricated by Explosive Welding

Microstructure and Mechanical Properties Investigations of Pure Titanium-Aluminum Alloy Composite Fabricated by Explosive Welding

A New Method for Preparing Titanium Aluminium Alloy Powder

Due to TiAl alloys’ excellent properties, TiAl alloys have received widespread attention from researchers. However, the high energy consumption and lengthy process of traditional preparation methods have always limited the large-scale application of TiAl alloys. This article develops a new method for preparing TiAl-based alloy powder via the magnesium thermal reduction of TiO2 in AlCl3-KCl molten salt. In this study, the proportion of AlCl3&KCl molten salts was determined. We conducted phase analysis on the final product by studying the changes in temperature and time. It was found that the TiAl3 alloy powder could be obtained by being kept at 750 °C for 2 h, with an oxygen content of 3.91 wt%. The reaction process for the entire experiment was determined through thermodynamic calculations and experimental analysis, and the principles of the reduction process are discussed.

Stagnation Bioconvection Flow of Titanium and Aluminium Alloy Nanofluid Containing Gyrotactic Microorganisms over an Exponentially Vertical Sheet

The pivotal aim of this research is to address a natural stagnation bioconvection flow of a hybrid nanofluid containing gyrotactic microorganisms over an exponentially stretching and shrinking vertical sheet. The mathematical formulation of simplified Navier-Stokes equations is made in the presence of a few parameters such as Prandtl number, concentration to thermal buoyancy ratio, microorganism to thermal buoyancy ratio, Lewis number, bioconvection Peclet number, bioconvection Lewis number, microorganisms concentration difference and buoyancy parameter. The two types of nanofluid containing titanium alloy (Ti6Al4V) and aluminium alloy (AA7075) immersed in water are considered for the investigation. In the analysis, the governing partial differential equations (PDEs) are transformed into a set of ordinary differential equations (ODEs) by a similarity transformation. The resulting equations are rewritten in MATLAB software through the Bvp4c method to obtain the solutions. The effects of hybrid nanofluid of titanium alloy (Ti6Al4V) and aluminium alloy (AA7075), microorganisms’ concentration difference parameter, and bioconvection Lewis Number are observed in this mathematical model in the presence of stretching and shrinking sheets. The numerical values are obtained for the skin friction coefficient, local Nusselt number, local Sherwood number, and local density of motile microorganisms for the reporting purpose. In addition, the profiles of the velocity, temperature, concentration, and microorganism are visualized as the main findings of this article.

Numerical simulation study on progressive bending of magnesium alloy grid panel

Research and development of magnesium alloy integral panel forming technology to replace existing titanium alloy and aluminum alloy panel materials are of great significance for saving aluminum and titanium resources. The material flow law during progressive bending technology of panel (PBTP) was analyzed by numerical simulation study. The deformation forming parameters of PBTP for Mg alloy grid panel and panel size control parameters are defined. The process parameters include deformation temperature, bending deformation coefficient, and reduction speed. The size and accuracy control parameters include the width of the bending die, pressing height, and feed rate. The panel radius was related to the width of the bending die and the height of the reduction. With increase of forming temperature, maximum damage coefficient, maximum equivalent stress and maximum equivalent strain reduce. With increase in bending deformation coefficient, maximum damage coefficient, maximum equivalent stress and maximum equivalent strain increase. Based on simulation and experimental results, reasonable forming parameters for PBTP of AZ31 Mg alloy grid panel was obtained. Magnesium alloy panel components were successfully processed by progressive bending technology. The influence of die width and pressing height on panel radius was analyzed. The numerical simulation results were consistent with experimental results. The maximum relative error was 3.5%.

Momentum and thermal transport analysis in MHD nanofluid through the thermally heated square conduit: Finite element method

ObjectiveThe purpose of this investigation is to report the thermal performance of water-based nanofluids with two different types of hybrid nanofluids for the cooling process of the radiator inside the thermally heated square cavity under the addition of thermal radiation and magnetic field by using the finite element method. Research gapThe heat transfer analysis of MHD nanofluid with the suspension of titanium alloy Ti6A14V and aluminum alloy AA7075 in cavity flow problems under the effects of thermal radiation and thermal boundary conditions by using the Galerkin finite element method is not reported before. NoveltyIn this numerical investigation, the novel mathematical model of two types of titanium alloy Ti6A14V (class of titanium) and aluminum alloy AA7075 is proposed first time in the cavity flows under the influence of a uniform magnetic field and non-uniform thermally heated bottom wall. The momentum and energy equations are updated with terms of magnetic field and thermal radiation, respectively. The cavity is filled with AA7075- Ti6A14V/water nanofluids. Two parallel vertical walls of the cavity are set at constant temperatures (Tc) and the top one is adiabatic while the temperature at the lower wall is taken as the variable. Method of solutionThe physical model is composed in terms of nonlinear differential equations and transformed into a dimensionless form by using suitable non-dimensional quantities. The Galerkin finite element method along with iterative Newton’s Raphson method is selected to simulate the problem and obtain the numerical solution with a high degree of accuracy. The results are illustrated for fixed Prandtl number Pr=10.0 throughout the calculation, Rayleigh number 1000≤Ra≤100000, nanoparticle volume friction 0.0≤ϕ≤0.05 Hartman number 0≤Ha≤10 and thermal radiation parameter 1.0≤Ra≤10.0. Both grid independence tests and comparison tests are directed to get the accuracy of the established model. Important findingsThe computational results revealed that the aluminum alloy (AA7075) alloys nanoparticles are more productive as compared to titanium (Ti6Al4V) alloy nanoparticles in terms of enhancing the thermal features of water-based nanofluid. The aluminum alloy nanofluid and titanium alloy nanofluid provide 3.9 % & 5.7 % and 2.9 % & 4.2 % more heat transfer at the bottom and side walls as compared to regular fluid. ApplicationsThe current nanofluid models are more efficient than the conventional model to control the heat transfer rate and flow phenomena. The computational results revealed that if the radiator is assembled by using the modern concept of hybrid nanofluid then that will increase the heat transfer of the engine and enhance the lifespan of the machinery.

Properties of various CaO-Al2O3-TiO2 refractories and their reaction behaviours in contact with Ti6Al4V melts

Vacuum induction melting technology is an important method for producing high-quality titanium alloy. The key challenge lies in the development of refractories with excellent chemical stability for titanium alloy corrosion. In this work, CaO-Al2O3-TiO2 refractories are proposed as the potential materials for Ti6Al4V alloy smelting. Four CaO-Al2O3-TiO2 refractories with different TiO2 contents were prepared and their reaction behaviours in contact with titanium aluminum melts were investigated in detail. When the refractory has a suitable content of CaTiO3 phase, it promotes the diffusion and mass transfer rate of ions and improves the sintering reaction activity, leading to good high temperature mechanical properties and corrosion resistance to titanium aluminum alloy. However, when the TiO2 component is excessive, CA6 has been completely wrapped by CaTiO3, and some CA6 grows abnormally, resulting in a decrease in high temperature mechanical properties of the refractory. Moreover, during the smelting of Ti6Al4V alloy, Al component reacts with CaTiO3 to produce metallic Ti and calcium aluminate phase with low melting point, resulting in degradation of refractory.

Lightweight Design and Finite Element Analysis of Brake Lever for Motorcycle Application

A lightweight component design contributes to the overall optimization of a system to be more effective and efficient. Then, it can lead to the contribution of a carbon footprint reduction. The research aimed to propose a novel lightweight brake lever design for motorcycle applications and numerically investigate its performance by comparing the proposed design with different utilized materials. The subject of the research was an optimized brake lever for motorcycle application. The materials used were aluminum alloy, structural steel, and titanium alloy. A Finite Element Method (FEM) analysis was employed to investigate the proposed brake lever design. Three proposed designs were introduced with the mass reduction in each optimization up to 50,9% of reduced mass. Maximum stress was observed on the most optimized design with a value of 297 MPa. The strain and total deformation were also investigated among the components. In the result, the stress-strain graph shows that the most optimized brake lever experiences the highest stress with the highest strain value. Furthermore, the highest safety factor is achieved with the utilization of titanium alloy, reaching the value of 6,28 for preliminary design and 3,1 for the most optimized component. However, the lightest component can be obtained using aluminum alloy.

A machine learning method for HTLCF life prediction of titanium aluminum alloys with consideration of manufacturing processes

Most conventional methods only consider the effects of materials and loading conditions when predicting the high-temperature low-cycle fatigue life of titanium aluminum alloys. However, the effects of manufacturing processes are not considered. To address this limitation, this paper proposes a machine learning method. First, the loading conditions are preliminarily filtered by physics knowledge. Second, the manufacturing processes and loading conditions are analyzed by using the average value of multiple mean impact values. Then, the variables that have little contribution to the output are filtered out, and the remaining variables are used as inputs. Finally, an optimized genetic algorithm-back propagation artificial neural network is established to predict the low-cycle fatigue life of the materials. The optimization methods are Levy flight and an adaptive adjustment mechanism of probability. Min-Max normalization is used to normalize and denormalize the data in the proposed method. A set of experimental data for Ti-685 is used to validate the proposed method. Moreover, the results show that the proposed method has better prediction accuracy than other methods.

Numerical simulation of milling cutter static stress with different materials using finite elements

An essential component of a milling machine is the milling cutter. It is possible to obtain the desired results by removing the excess material from the workpiece that is causing the problem. The most common materials used to manufacture milling cutters are aluminium, cemented carbides, steel tools, ceramics, and titanium. Aside from the standard materials, you may wish to consider whether some of the following materials would also be suitable for the manufacture of milling cutters. As well as the standard materials, this is an addition. This research involves the design of a typical milling cutter and the development of a model using the CATIA V5 software for simulation in three dimensions. In the following step, the data is imported into the analysis software ANSYS. According to the designed model, static analyses are conducted on various materials, including titanium alloy, aluminium alloy, and stainless steel. In this study, the stress distribution and deformation of developed models are investigated as a function of time during the development of the model. These three materials are also subjected to a stable thermal analysis during the transient thermal analysis. Three materials can be used at their maximum temperature according to the simulation analysis of the materials.

Finite element analysis of wheel rim by additive manufacturing materials

Due to the number of possible uncertainties, and the non-linearity of variables, it is difficult to analyze the stresses induced in the wheel rim. This work covers the application of additive manufacturing (AM) materials to a particular product, wheel rim, for design and analysis to know how the new materials are performing under boundary conditions. The design work of the wheel rim is done by using computer-aided design (CAD) software, CATIA V5. After that, the designed model is brought into ANSYS software for the analysis work. Static and modal analysis is carried out using ANSYS software by considering two different materials namely aluminum alloy, Al-Si-10 Mg, and titanium alloy, Ti-6Al-4 V. ANSYS analysis shows, the Al-Si-10 Mg alloy wheel rim is subjected to more stress, and more deformation compared to the Ti-6Al-4 V alloy wheel rim. After observing all the results, it has been seen that the titanium alloy, Ti-6Al-4 V performed better than the aluminium alloy, Al-Si-10 Mg.

VIBROACOUSTIC SOUNDPROOFING FOR HELICOPTER INTERIOR

As VIP passengers generally want to fly civil and executive jets where vibratory and acoustic environment is smoother than on the normal jets. Helicopter interior noise is generated by main and tail rotors, engines, main gearbox, and aerodynamic turbulence (Lu et al., 2018). Because of these sources, the tonal and broadband noise is incredibly high and needs to be reduced. Conventional passive system (soundproofing) is the best way to control the acoustic of the cabin whereas active systems (active vibration and noise control) are not completely reliable or applicable. The design of the soundproofing may be researched by simulation using one of these programs: ANSYS, SOLIDWORKS 2020 and ACOUSTIC analysis Vibroacoustic Monitoring (VAM) approach. The analyses were performed from frequency ranges, 5-10Hz and 0-2000Hz then transformed into frequency velocity domain using Proudman’s equations (Lu et al., 2017). Soundproofed ANSYS models are validated using instantaneous sound pressure levels measured within the helicopter during flight. The acoustic detection method for GAZELLE is also performed successfully in SOLIDWORKS for aluminum alloy and titanium alloy, this proves the relationship between acoustic power levels and material configuration. The noise coefficient responses of interior materials are used as main index for soundproofing helicopter interiors. The results of this research can be used for implementation of VAM approach for soundproofing helicopter interiors.

The inhibitive action of 2-mercaptobenzothiazole on the porosity of corrosion film formed on aluminum and aluminum–titanium alloys in hydrochloric acid solution

2-Mercaptobenzothiazole (2-MBT) in a solution of 0.5 M HCl is an effective corrosion inhibitor for aluminum and aluminum–titanium alloys. Tafel polarization and electrochemical impedance spectroscopy (EIS) were employed to assess this heterocyclic compound’s anticorrosive potential and complementary by scanning electron microscope (SEM) and calculating porosity percentage in the absence and presence of various inhibitor concentrations. Inhibition efficiency (IE%) was strongly related to concentration (10–6–10–3 M). Temperature’s effect on corrosion behavior was investigated. The data exhibited that the IE% decreases as the temperature increases. An increase in activation energy (Ea) with increasing the inhibitor concentration and the decrease in the IE% value of the mentioned compound with raising the temperature indicates that the inhibitor molecules are adsorbed physically on the surface. Thermodynamic activation parameters for Al and Al–Ti alloy dissolution in both 0.5 M HCl and the inhibited solution were calculated and discussed. According to Langmuir’s adsorption isotherm, the inhibitor molecules were adsorbed. The evaluated standard values of the enthalpy (Delta {H}_{ads.}^{o}), entropy (Delta {S}_{ads.}^{o}) and free energy changes (Delta {G}_{ads.}^{o}) showed that Delta {H}_{ads.}^{o} and Delta {G}_{ads.}^{o} are negative, while Delta {S}_{ads.}^{o} was positive. The formation of a protective layer adsorbed on the surfaces of the substrates was confirmed with the surface analysis (SEM). The porosity percentage is significantly reduced in the inhibitor presence and gradually decreased with increasing concentration. Furthermore, the density functional theory (DFT) and Monte Carlo (MC) simulations were employed to explain the variance in protecting the Al surface from corrosion. Interestingly, the theoretical findings align with their experimental counterparts. The planarity of 2-MBT and the presence of heteroatoms are the playmakers in the adsorption process.

Emerging Functional Metals in Additive Manufacturing

Additive manufacturing (AM) is a disruptive technology which continues to challenge conventional manufacturing methods. New generations of materials for metal AM are sought to enable components with new functionalities and to save costs. However, many within the AM industry are primarily focused on metal alloys such as titanium alloys, cobalt alloys, nickel superalloys, aluminum alloys or stainless steels. This article presents a detailed overview of emerging non‐ferrous metals in the AM industry and their recent development. The potential and challenges of these materials and their adoption by AM are highlighted and compared to those of conventional materials. Furthermore, qualification pathways and supply issues for newly developed materials are discussed. This perspective is based on literature review and a thorough analysis of the metal AM industry.

Additive Manufacturing Processes in Selected Corrosion Resistant Materials: A State of Knowledge Review

Additive manufacturing is an important and promising process of manufacturing due to its increasing demand in all industrial sectors, with special relevance in those related to metallic components since it permits the lightening of structures, producing complex geometries with a minimum waste of material. There are different techniques involved in additive manufacturing that must be carefully selected according to the chemical composition of the material and the final requirements. There is a large amount of research devoted to the technical development and the mechanical properties of the final components; however, not much attention has been paid yet to the corrosion behaviour in different service conditions. The aim of this paper is to deeply analyze the interaction between the chemical composition of different metallic alloys, the additive manufacturing processing, and their corrosion behaviour, determining the effects of the main microstructural features and defects associated with these specific processes, such as grain size, segregation, and porosity, among others. The corrosion resistance of the most-used systems obtained by additive manufacturing (AM) such as aluminum alloys, titanium alloys, and duplex stainless steels is analyzed to provide knowledge that can be a platform to create new ideas for materials manufacturing. Some conclusions and future guidelines for establishing good practices related to corrosion tests are proposed.

Joining of Aluminum Alloy AA7075 and Titanium Alloy Ti-6Al-4V through a Friction Stir Welding-Based Process

Combining dissimilar parts has become imperative for developing the structures based on lightweight materials, such as metal alloys, polymers or polymer matrix composites, and this has become one of the solutions to reverse the current trend of CO2 emissions in the transport sector. However, given the usual property disparities, joining dissimilar materials in multi-material and multi-purpose structures raises new engineering challenges. Advanced joining processes, such as friction stir welding (FSW), have emerged and have been applied across several sectors as a promising alternative to conventional joining processes, such as mechanical fastening or adhesive bonding. In the present work, and in order to avoid the development of intermetallic compounds (IMCs), a different approach from the conventional technique of friction stir welding was applied to the production of dissimilar overlapping joints. These dissimilar joints were fabricated using a high strength aluminum alloy (AA7075-T651) and a titanium alloy (Ti-6Al-4V), both materials widely used in automotive, aeronautics and space industries. To perform a systematic investigation, the Taguchi method was used to determine the process parameter combinations to enable the fabrication of this type of dissimilar joints. The joints were subjected to quasi-static tensile shear tests to assess their mechanical performance and were compared to conventionally riveted joints in different configurations, namely, single and double connection points. The joints produced by the FSW based method showed higher mechanical performance. To assess the local properties, some of the fractured regions of the joints were subjected to hardness assessments, revealing no significant change in the hardness in the tested areas. Finally, a statistical study was performed to analyze the main effects and interactions of the process parameters, to identify their influences on the mechanical performance of the joints.

A short and long crack growth model with mean stress correction based on cyclic resistance curve

In the study, the Chapetti cyclic resistance curve is modified by a R-dependence model based on the cyclic strain energy density to account for the mean stress effects on the long crack propagation threshold and fatigue limit. Accordingly, the crack growth model of the modified NASGRO with mechanically short crack extension and Kitagawa-Takahashi diagram are derived with mean stress sensitivity. Relatively good accuracy can be achieved in terms of the near-threshold propagation behaviors and SN curves at high cycle regime including engineering aluminum alloys and titanium alloys.

Numerical Investigation on the Performance of Prosthetic Running Blades by Using Different Materials

The amputation of a lower limb for humans is one of the most traumatic experiences, both physically and emotionally. Prosthetic running blades provide disabled persons with an opportunity to participate in sports and thus help to improve their psychological health. They also allow them to participate in activities that were previously unavailable to them due to financial constraints. In the current study, we looked at how different materials affected the functionality of prosthetic running blades. We investigated the static behavior of a prosthetic running blade using finite element modeling. Under various load circumstances, we conducted numerical simulation using a variety of materials, including titanium alloy (grade 5), carbon fiber, stainless steel (AISI 316), and aluminum alloy (2024 T4). We studied three major load conditions: rest (700 N), walking (1400 N), and running (2200 N). To understand the performance depending on the selection of materials, we evaluated total deformation, equivalent stress, and strain energy in the design of our experiment. The titanium alloy is more durable and has a higher tensile strength. The high cost of manufacture for titanium alloy, however, is a major deterrent to its use in running blades. It was noticed that the aluminum alloy (2024 T4) blade goes under much deformation as compared to titanium and carbon fiber-made running blades. Furthermore, carbon fibers offer excellent mechanical properties, which are essential for creating running blades. It has outstanding tensile properties. Additionally, the low density of carbon fiber has the added advantage of making running blades lighter.

Static Behavior of a Prosthetic Running Blade Made from Alloys and Carbon Fiber

Prosthetic running blades offer a solution for individuals with disabilities to engage in sports, benefiting them both psychologically and physiologically. Furthermore, a good prosthetic running blade in terms of performance and cost is rarely available to all disabled persons. In this study, we have examined how various materials impact the static behavior of the prosthetic running blade. A finite element numerical analysis was conducted on a prosthetic design to investigate this effect. We have used different materials for investigation such as aluminum alloy (2024 T4), stainless steel (AISI 316), carbon fiber, and titanium alloy (grade 5), under different load conditions. The load conditions have been varied mainly to three conditions, namely, rest (700 N), walking (1400 N), and running (2100 N). In our experimental design, we studied total deformation, equivalent stress, and strain energy to understand the performance based on material choice. It was noticed that the aluminum alloy (2024 T4) blade goes under much deformation when compared to titanium- and carbon fiber-made running blades. The least amount of overall deformation occurs in carbon fiber under varying load conditions. Carbon fiber appears to be the most profitable option due to its lowest cost per running blade. Titanium alloy grade 5, carbon fiber, AISI 316 stainless steel, and aluminum 2024 T4 alloy cost a total of 78.1, 48.5, 67.6, and 20.9 USD, respectively. It is evident that titanium alloy materials carry a higher price compared to alternative materials.