Optimization of machining parameters for turning operation of heat-treated Ti-6Al-3Mo-2Nb-2Sn-2Zr-1.5Cr alloy by Taguchi method.

TC21 alloy is a high-strength titanium alloy that has been gaining attention in various industries for its excellent combination of strength, toughness, and corrosion resistance. Given that this alloy is hard to cut material, therefore this study aims to optimize the process parameters of Turing this alloy under different conditions (i.e. as-received alloy, and heat-treated alloy). The L9 Taguchi approach-base orthogonal array is used to determine the optimum cutting parameters and the least number of experimental trials required. The achievement of this target, three different cutting parameters are used in the experimental work; each cutting parameter has three levels. The cutting speeds are chosen as 120, 100, and 80 m/min. The feed rates' values are 0.15, 0.1, and 0.05, mm/rev, and the depth of cut values are 0.6, 0.4, and 0.2 mm. After applying three steps of heat treatment (First step: is heating the sample to 920 °C for 1 h then decreasing to 820 °C also for 1 h, second step: cooling the sample to room temperature by water quenching (WQ), the third step: holding the sample at 600 °C for 4 h (Aging process)). The results revealed that the triple heat treatment led to the change in the microstructure from (α + ß) to (α + ß) with secondary α platelets (αs) formed in residual ß matrix leading to a decreased surface roughness by 56.25% and tool wear by 24.18%. The two most critical factors that affect the tool insert wear and surface roughness are the death of cut and cutting speed, which contribute 46.6% and 46.7% of the total, respectively. Feed rate, on the other hand, has the least importance, contributing 20.2% and 31.9% respectively.

Influence of heat treatment processes on microstructure evolution, tensile and tribological properties of Ti6Al4V alloy.

The influence of heat treatment processes on microstructure, tensile and tribological properties of Ti6Al4V alloy was investigated. The specimens were heated for 30 min at 925 °C and then cooled at various rates by water quenching, air cooling, and furnace cooling. After that, the samples were aged for four hours at 600 °C. Three phases make up the microstructure: primary α-phase (αp), secondary α-phase (αs), and retained ß-phase (ßr). Cooling in the air and water followed by aging (AC + Aging and WQ + Aging) resulted, αs-phase precipitating inside ßr-phase. The highest hardness of 35 HRC was recorded for WQ + Aging specimen due to existence of a high amount of ßr-phase and precipitation of αs-phase. On the other hand, the lowest hardness of 26 HRC was obtained for the FC specimen. AC specimen achieved the highest elongation value of 14%. However, WQ + Aging specimen exhibited the highest ultimate tensile strength of 1028 MPa. For WQ + Aging and AC + Aging specimens, the ideal balance of strength and elongation was discovered. The wear resistance of solution-treated specimens was significantly improved by the aging process and 125% improvement could be achieved in WQ compared to WQ + Aging specimens.

Impact of thermal oxidation parameters on micro-hardness and hot corrosion of Ti-6Al-3Mo-2Nb-2Sn-2Zr-1.5Cr alloy.

Protective oxide layers on Ti-6Al-3Mo-2Nb-2Sn-2Zr-1.5Cr (TC21) alloy with equiaxed microstructure considerably influence micro-hardness and hot corrosion resistance. The present work's thermal oxidation of TC21 alloy was performed at 600, 700, and 800 °C for 5, 20, and 50 h durations. Hot corrosion methods in NaCl and NaCl + Na2SO4 salt media were applied to raw (unoxidized) and oxidized samples at 600 and 800 °C for 50 h. Hot corrosion was conducted at 600 °C for 5 cycles with 10-h steps. The best oxide layer thickness was observed at 800 °C, which increased with increased oxidation time and temperature. The surface hardness of the oxide layer at 800 °C was 900 ± 60 HV0.05 owing to the formation of TiO2 and Al2O3 phases. Raw material hardness was 342 ± 20 HV0.05, increasing threefold due to thermal oxidation. In the case of NaCl, weight loss dominated all samples except at 800 °C for 5 h. In the case of NaCl + Na2SO4, weight gain occurred at 600 and 800 °C for 5 h. Weight loss occurred for the raw samples and those processed at 800 °C for 20 and 50 h, where the oxide layer flaked off. Surface hardness increased upon hot corrosion testing because of the formation of brittle phases, such as TiO2 and Na4Ti5O12. Samples that oxidized at 800 °C for 5 h had the highest hardness and corrosion resistance.

Worn surface topography and mathematical modeling of Ti-6Al-3Mo-2Sn-2Zr-2Nb-1.5Cr alloy.

This study aims at investigating worn surface topography and mathematical modeling of annealed Ti-6Al-3Mo-2Sn-2Zr-2Nb-1.5Cr alloy using response surface methodology (RSM). The alloy was subjected to three different regimes in order to study their effect on mechanical properties. First regime was applying cold deformation by compression until 15% drop in height at room temperature. The second regime was performing solution treated on the deformed samples at 920 °C for 15 min then air-cooled (AC) to ambient temperature. Third regime was applying aging on the deformed and solution treated specimen for 4 hr at 590 °C followed by air-cooling. Three different velocities (1, 1.5, and 2 m/s) were adopted to conduct dry sliding wear according to the experimental design technique (EDT). Gwyddion and Matlab softwares were used to detect worn surface photographs analytically and graphically. Maximum hardness of 425 HV20 was obtained for AC+Aging specimen, while minimum hardness of 353 HV20 was reported for the annealed specimen. Applying aging process after solution treatment enhanced considerably the wear property and this enhancement reached 98% as compared to the annealed condition. The relationship between input factors (hardness & velocity) and responses (Abbott Firestone zones) was demonstrated using analysis of variance (ANOVA). The best models for Abbott Firestone zones (high peaks, exploitation, and voids) produced accurate data that could be estimated for saving time and cost. The results showed that the average surface roughness increases with increasing sliding velocity for all conditions except AC+Aging condition where the average surface roughness decreased with increasing sliding velocity. The results revealed that at low velocity and hardness, the material gives the highest exploitation zone (86%). While at high velocity and hardness, the material gives the lowest exploitation zone (70%). In general, the predicted results of mathematical model showed close agreement with experimental results, creating that models could be utilized to predict Abbott Firestone zones satisfactorily.

Enhancement of quasi-static compression strength for aluminum closed cell foam blocks shielded by aluminum tubes.

Aluminum closed cell foam blocks are created with a volume of 1 inch3 which consist of aluminum foam parts shielded with part of aluminum tube and in some types reinforced with inner aluminum tubes. Blocks have been made to overcome some existing problems in metallic foam used to protect some applications parts from impacts as a sacrificial part. Metallic foam has three main categories sandwich panels, filled tubes and corrugated sheets. Quasi-static compression tests have been applied on 12 blocks with different shapes and compared with pure aluminum foam blocks as a reference. Results display the enhancement of mechanical properties of blocks like yield strength (SY), crushing strength (Sc) and densification strength (Sd), compression at strain 70%, as well as absorbed energy (area of compression under the curve). The highest value for yield strength (5.87 MPa) was registered for Finger phalanxes cube block (FP-0.1 Sq.). While the highest value for densification strength (21.7 MPa) was registered for spine cylinder block (SV8-0.17 C25). The registered results for samples apparent the highest value for energy dissipation density (Edd) is 40.52 J/in3 (91% enhancement) and crushing strength (8.61 MPa) was registered for Finger phalanx cylinder block (FP-0.17 C25). The lowest value for Edd is 14.16 J/in3 (less than pure aluminum foam block value by 33%), SY = 0.42 MPa, Sc = 3.21 MPa, and Sd = 4.46 MPa, registered for thin wall Ear canal cylinder block (EC8-0.075 C26.5). Best mechanical properties had been achieved for Finger phalanx cylinder block (FP-0.17 C25) and spine cylinder block (SV8-0.17 C25).

Modeling of wear resistance for TC21 Ti-alloy using response surface methodology.

This study investigated the effect of heat treatment processes on the dry sliding wear resistance of the TC21 Ti-alloy at several levels of normal load and sliding speed. Response Surface Methodology (RSM) has been used as a design of the experiment procedure. OM and FESEM besides XRD analysis were used for results justification. Highest hardness of 49 HRC was recorded for WQ + Aging specimens due to the plenty of α″ which decomposed to αs and the more αs, while the lowest hardness of 36 HRC was reported for WQ specimens. The results revealed that specimens subjected to water quenching and aging (WQ + Aging) under extreme load and speed conditions (50 N and 3 m/s), possessed the poorest wear resistance although they had the highest hardness. While those left in the annealed condition revealed the highest wear resistance although they had much lower hardness when compared to other conditions. A mathematical polynomial model for wear resistance expressed in wear rate was developed, validated then used to get the optimum parameters.

Effect of oxide layers formed by thermal oxidation on mechanical properties and NaCl-induced hot corrosion behavior of TC21 Ti-alloy.

In the current study on TC21 Ti-alloy (6.5Al-3Mo-1.9Nb-2.2Sn-2.2Zr-1.5Cr), the thermal oxidation formed oxide layers that considerably influenced mechanical properties (hardness and wear). TC21 specimens were oxidized at 600, 700, 800, and 900 °C for 5, 20, and 50 h. NaCl-induced hot corrosion testing was carried out on raw (un-oxidized) and oxidized specimens at 600 and 800 °C for 50 h. The cyclic testing was performed at 600 °C for durations of 5, 10, 20, 30, 40, and 50 h. The average thickness of the layer grew with increasing oxidation time and temperature. A thin oxide layer (average 0.16 µm) was generated by oxidation at a temperature of 600 °C for a duration of 5 h, and at 800 °C, a large oxide layer of 10.8 µm thickness was formed. The most significant surface hardness of 1000 ± 150 HV0.05 was produced for the layer oxidized at 900 °C. On the other hand, the lowest hardness of 360 ± 150 HV0.05 was recorded for the raw materials. Best wear resistance had been achieved for specimens oxidized at 800 °C. During NaCl hot corrosion test, the weight loss of the raw specimen was 6.4 mg/cm2 due to the flaking off of the corrosion product. However, for specimens oxidized at 600 °C for 50 h, weight loss after corrosion testing was 0.54 mg/cm2, less than that of the specimen before corrosion. Oxidized specimens at 800 °C exhibited the best mechanical characteristics and corrosion resistance.

Mathematical modeling of wear behavior and Abbott Firestone zones of 0.16C steel using response surface methodology.

The effects of applied pressure and running velocity on wear behavior as well as Abbott Firestone zones of low carbon steel (0.16C) were evaluated using response surface methodology (RSM). At room temperature, three different pressures (0.5, 1.5, and 2.5 MPa) and three different velocities (1.5, 2.25, and 3 m/s) were used to conduct dry sliding wear trials utilizing the pin-on-disc method according to the experimental design technique (EDT). The experiments were created using central composite design (CCD) as a starting point. The relationship between input factors (pressure and velocity) and responses (wear rate and Abbott Firestone zones) of 0.16C steel was demonstrated using analysis of variance (ANOVA). The best models for wear rate as well as Abbott Firestone zones produced accurate data that could be estimated, saving time and cost. The results revealed that pressure had the greatest impact on the alloy's dry sliding wear behavior of the two variables studied. In general, the predicted result shows close agreement with experimental results and hence created models could be utilized for the prediction of wear behavior and Abbott Firestone zones satisfactorily.

Erratum: Elshazli et al. Laser Surface Modification of TC21 (α/ß) Titanium Alloy Using a Direct Energy Deposition (DED) Process. Micromachines 2021, 12, 739.

In the original article [...].

Laser Surface Modification of TC21 (α/ß) Titanium Alloy Using a Direct Energy Deposition (DED) Process.

The TC21 alloy (Ti-6Al-3Mo-1.9Nb-2.2Sn-2.2Zr-1.5Cr) is considered a new titanium alloy that replaced the commercial Ti-6Al-4V alloy in aerospace applications due to its higher operating temperatures. Recently, direct energy deposition was usually applied to enhance the hardness, tribological properties, and corrosion resistance for many alloys. Consequently, this study was performed by utilizing direct energy deposition (DED) on TC21 (α/ß) titanium alloy to improve their mechanical properties by depositing a mixture powder of stellite-6 (Co-based alloy) and tungsten carbides particles (WC). Different WC percentages were applied to the surfaces of TC21 using a 4 kW continuous-wave fiber-coupled diode laser at a constant powder feeding rate. This study aimed to obtain a uniform distribution of hard surfaces containing undissolved WC particles that were dispersed in a Co-based alloy matrix to enhance the wear resistance of such alloys. Scanning electron microscopy, energy dispersive X-ray analysis (EDAX), and X-ray diffractometry (XRD) were used to characterize the deposited layers. New constituents and intermetallic compounds were found in the deposited layers. The microhardness was measured for all deposited layers and wear resistance was evaluated at room temperature using a dry sliding ball during a disk abrasion test. The results showed that the microstructure of the deposited layer consisted of a hypereutectic structure and undissolved tungsten carbide dispersed in the matrix of the Co-based alloy that depended on the WC weight fraction. The microhardness values increased with increasing WC weight fraction in the deposited powder by more than threefold as compared with the as-cast samples. A notable enhancement of wear resistance of the deposited layers was thus achieved.