Foreign object damage (FOD) refers to the damage that generally takes place in aero engine fans and compressor blades, due to the ingestion of hard particles/debris during aeroplane take-off, taxiing, or landing. Such damage can reduce the fatigue life expectancy of the turbine engine components by 50%. Residual stresses and small microcracks induced by the high speed FOD impacts are two root causes that result in premature failure of these components. One way to mitigate the FOD related fatigue failure is to induce deep compressive residual stress into the surface. Among the available techniques that can induce such compressive residual stress, laser shock peening (LSP) has been found to be beneficial in improving the fatigue strength. In this study aerofoil-shaped Ti-6Al-4V leading edge specimens were laser shock peened. Subsequently, FOD was introduced onto the leading edge specimen through ballistic impacts of a cube edge at angles of 0° and 45° to the leading edge. The effect of foreign object damage (FOD) on the pre-existing compressive residual stress field associated with the laser shock peening (LSP), and its change upon solely low cycle fatigue (LCF) as well as combined low and high cycle fatigue cycling has been studied. The residual stress distribution and their redistribution upon fatigue cycling were mapped around the FOD notch, using synchrotron X-ray radiation and the contour method. The results suggest that under both impact angles, the FOD event superimposed a significant additional residual stress on top of the pre-existing stress associated with the LSP process. It has been observed that the FOD notch created by 45° impact was asymmetric in shape, and had differential notch depth between the entry and exit side. However, FOD damage that is created at 0° impact appeared as a sharp V notch. A higher amount of residual stresses were produced under 0° impact condition than at 45°. It has been found even though the FOD induced residual stresses relax, residual stresses due to LSP treatment remain highly stable even in the worst condition where a 7 mm long crack was grown from a 45° notch. The plastic zone sizes ahead of a crack tip was estimated for both 0° and 45° FOD impact, and the fatigue crack growth rates are predicted utilizing the measured residual stress distribution.

Titanium alloys are strong candidates for the aerospace industry and biomaterial applications because of their low density, high strength-to-weight ratio and very high strength even at temperatures up to 600°C. Like many other engineering alloys, titanium alloys are prone to strong preferred crystallographic orientation development during thermomechanical processing. Part of the titanium processing route is to heat treat the material above the β transus for the purpose of homogenization and associated phase transformation. This heat treatment dramatically affected the microstructure and texture evolution. Theoretically, such heat treatment should result in a nearly random texture if all variants during α→β→α phase transformation are active. In reality, significant textures are observed after such a heat treatment process. The present project aims at developing a detailed understanding of the root cause for this relatively strong texture by means of EBSD and in-situ neutron diffraction studies. The effect of β grain growth on variant selection during β to α phase transformation has been investigated by using two variants of Ti-6Al-4V with and without 0.4 wt% yttrium addition. The aim of adding yttrium was to control β grain growth above the β transus by pinning grain boundaries with yttria. Both materials were first thermomechanically processed to generate a similar starting microstructures and crystallographic textures. Subsequently, both materials were solution heat treated above the β transus followed by slow cooling to promote growth of the α lath structure from grain boundary α. Detailed EBSD and in situ neutron diffraction analysis were carried out to study microstructure and texture evolution. The variant selection calculation suggests that more variant selection occurred in convectional material with a large grain size compared to material with yttrium addition. In situ measurements showed that β texture strengthened significantly above the β transus with increasing β grain size. There was no significant variant selection during α→β transformation; variant selection noticeably increased during β→α transformation with increasing β grain size. Additional interrupted cooling experiments followed by EBSD analysis showed early nucleation of α variants with a 'butterfly morphology' from β grain boundaries that have a pair of β grain with a common <110> pole. These observations suggest reduced nucleation energies for α formation in such circumstances allowing extensive growth of these α variants into unoccupied β grains making it a dominant variant. The influence of rolling temperatures (i.e. at 800 ºC and 950 ºC) to produce different starting texture, on texture evolution and variant selection during α→β→α transformation was also investigated. Laboratory X-ray, EBSD and in-situ neutron diffraction texture analyses were carried out. Even though the transformation texture is stronger at 800 ºC, the degree of variant selection is stronger in materials rolled at950 ºC compared to material rolled at 800 ºC. Here, the enhanced variant selectionfor the material rolled at 950 ºC was related to the different β texture. It is suggested that the combination of a particular β texture components promote variant nucleation that can increase the likelihood of having β grain pairs with a common <110> pole.

The challenges in the deposition of dissimilar materials are mainly related to the large differences in the physical and chemical properties of the deposited and substrate materials. These differences readily cause residual stresses and intermetallic phases. This has led to the development of functionally graded materials which exhibit spatial variation in composition. Laser direct metal deposition due to its flexibility, it offers wide variety of dissimilar and functionally graded materials deposition. Despite considerable advances in process optimization, there is a rather limited understanding of the role of metallurgical factors in the laser deposition of dissimilar and functionally graded alloys. The aim of this work is to understand and explain mechanisms occurring in diode laser deposition of dissimilar materials and functionally graded materials. The first part of this work addressed diode laser deposition of Inconel 718 nickel alloy to Ti-6Al-4V titanium alloy. Here, the effect of laser pulse parameters and powder mass flow rates on the stress formation and cracking has evaluated by experiment and numerical techniques. Results showed that the clad thickness was an important factor affecting the cracking behaviour. In the second part of this study, an image analysis technique has been developed to measure the surface disturbance and the melt pool cross section size during laser direct metal deposition of Inconel 718 on a Ti-6Al-4V thin wall. It was noted that under tested conditions the overall melt pool area increased with the increase in powder flow rate; the powder carrier gas flow rates also seemed to play important roles in determining the melt pool size. In the third part of this study, a parametric study on the development of Inconel 718 and Stainless steel 316L continuously graded structure has been carried out. Results suggested that microstructure and other mechanical properties can be selectively controlled across the deposited wall. The results presented in this dissertation can be used as a metallurgical basis for further development of dissimilar and functionally graded manufacturing using LDMD technique, guiding future manufacturing engineers to produce structurally sound and microstructurally desirable laser deposited samples.

The widespread use of titanium and its alloys in structural applications has been limited to few highend applications. The dominant reason for this being cost implications. These high costs arise from extracting titanium from its mineral form as well as that of the manufacturing processes to develop a final product. Since producing titanium products includes expensive starting stock, high machinability costs and high wastage, a need for a process that may minimize one or more of these factors is necessary. One such technology that exists is a branch of powder metallurgy (PM), direct powder rolling (DPR) which allows for a continuous approach to produce strip or sheet metal. Products developed by this process are however known to possess inferior properties to its wrought counterpart. The present study comprises of a parametric study observing how two different blends of powder differ in the development of Ti-6Al-4V strip by employing the blended elemental (BE) approach to direct powder rolling. The objectives of this work include predicting the compaction behavior of the two respective blends during powder rolling to inform the production of high density green strip and to compare the outcomes of the prediction method to experimentally determined results using a gravity-fed laboratory-scale rolling mill with roll diameter of 265 mm and roll width of 150 mm. Johanson’s rolling theory was applied to predict rolling outcomes and a fixed set of rolling parameters were implemented for the simulation and experimental segment of this dissertation. The two blends being investigated include blending titanium powder with an elemental blend consisting of aluminium and vanadium powders (B1) and a master alloy blend of a 60Al-40V master alloy (B2). These two blends were used to validate the Johanson simulated rolling data. Fixed parameters applied to the rolling mill included using a roll speed of 14 rpm, roll face width of 65 mm and gravity-fed hopper outlet diameter of 25 mm. Variable roll gaps of 0.5, 1 and 1.5 mm were studied. Average relative green densities of B1 and B2 strips achieved at a roll gap of 1 mm were 77% and 73% respectively. Rolling performance of the B1 powder blend were higher than that of B2, reaching higher green densities and showing superior formability, as rolling at smaller roll gaps was achievable for B1 and not B2. Green strength of B1 and B2 strips at a roll gap of 1 mm reflected similar outcomes where B1 strips required a greater breaking load to fracture samples when compared to B2 indicating a stronger self-supporting compact. Furthermore, the Johanson rolling model proved to overestimate reasonable roll pressure values, although, the general trend of compactibility between B1 and B2 powder blends was reasonably predicted showing B1 to be more compressible than B2 during powder rolling. iv Subsequent sintering at 1200 °C for 3 hours in a vacuum environment was applied to green strips to further densify and homogenize strips. Average relative sintered densities achieved for B1 and B2 strips rolled at a roll gap of 1 mm were 78% and 87% respectively. While green densities of B1 strips were higher than that of B2 strips, it was evident that the addition of the 60Al-40V master alloy to blend B2 resulted in superior sinterability as final sintered densities surpassed that of B1, even when starting at a lower green density after rolling. SEM/EDX was used to evaluate what effect sintering had on homogenization. A standard wrought Ti-6Al-4V specimen was used as the benchmark to compare homogenization results. B2 strips homogenized more than B1 strips when comparing to the baseline wrought sample. It was concluded that both B1 and B2 powders used to create Ti-6Al-4V strip by direct powder rolling (DPR) exhibited high levels of porosity and a subsequent step is necessary to fully densify the material. While B1 strips exhibit superior rollability with higher green densities and green strength; after applying a sintering practice to both B1 and B2 strips, B2 sintered densities surpassed those of B1 and prove to homogenize to a greater degree than B1 strips. The superior roll compaction ability and inferior sinterability for B1 powders was attributed to the elemental powder, aluminium. While the addition of ductile aluminium to B1 aids roll compaction, its low melting point results in large pores evolving at sintering temperatures almost twice its melting point.

abstract: Additive manufacturing (AM) has been extensively investigated in recent years to explore its application in a wide range of engineering functionalities, such as mechanical, acoustic, thermal, and electrical properties. The proposed study focuses on the data-driven approach to predict the mechanical properties of additively manufactured metals, specifically Ti-6Al-4V. Extensive data for Ti-6Al-4V using three different Powder Bed Fusion (PBF) additive manufacturing processes: Selective Laser Melting (SLM), Electron Beam Melting (EBM), and Direct Metal Laser Sintering (DMLS) are collected from the open literature. The data is used to develop models to estimate the mechanical properties of Ti-6Al-4V. For this purpose, two models are developed which relate the fabrication process parameters to the static and fatigue properties of the AM Ti-6Al-4V. To identify the behavior of the relationship between the input and output parameters, each of the models is developed on both linear multi-regression analysis and non-linear Artificial Neural Network (ANN) based on Bayesian regularization. Uncertainties associated with the performance prediction and sensitivity with respect to processing parameters are investigated. Extensive sensitivity studies are performed to identify the important factors for future optimal design. Some conclusions and future work are drawn based on the proposed study with investigated material. / Dissertation/Thesis / Masters Thesis Mechanical Engineering 2020

No description available.

Tento projekt se zabývá optimalizací chladicích kanálků nového vrtáku navrženého společností SECO Tools pro obrábění titanové slitiny Ti-6Al-4V. Cílem tohoto projektu je optimalizovat průměr a polohu chladicích kanálků na hřbetu tak, aby se snížila teplota vrtáku a tím i životnost nástroje. Nový vrták je použit pro provedení vrtacích zkoušek s použitím konvenční řezné kapaliny (emulze s 7% koncentrací) při tlaku 40 barů. Získané výsledky jsou porovnány s výsledky získanými pomocí dostupného standardního vrtáku od společnosti SECO Tools pro vrtání obrobku Ti-6Al-4V. Teplotní CFD model je vytvořen pro různé hodnoty vstupních tlaků kapaliny pomocí turbulentího modelu k- SST a tepelného zatížení vypočítaného na základě vrtacích zkoušek. Výsledky pro standardní a prototypové vrtáky jsou navzájem porovnávány, s ohledem na průtok, teplotu vrtáku, rychlost kapaliny a přenos tepla do MWF. Následně je model použit k ověření optimalizovaných návrhů.

No description available.

No description available.

No description available.