Ti-6Al-4V, known for high strength-to-weight ratio and good resistance to corrosion, has been widely used in aerospace, biomedical, and high-performance sports applications. A wide range of physical and mechanical properties of Ti-6Al-4V can be achieved by varying the microstructures via deformation and recrystallization processes. The aim of this thesis is to establish a microstructure-sensitive fatigue analysis approach that can be applied in engineering applications such as fretting fatigue to permit explicit assessment of the influence of microstructure. In this thesis, crystal plasticity constitutive relations are developed to model the cyclic deformation -TiAl has beenabehavior of Ti-6Al-4V. The development of the slip bands within widely reported and has been found to play an important role in deformation and fatigue behaviors of Ti-6Al-4V. The shear enhanced model is used to simulate the formation and evolution of slip bands triggered by planar slip under static or quasi-static loading at room temperature. Fatigue Indicator Parameters (FIPs) are introduced to reflect driving force for the different crack formation mechanisms in Ti-6Al-4V. The cyclic stress-strain behavior and fretting fatigue sensitivity to microstructure and loading parameters in dual phase Ti-6Al-4V are investigated.

Thesis (MScEng (Industrial Engineering))--University of Stellenbosch, 2009. / The titanium alloys have found wide application in the aerospace, biomedical and automotive industries. Soaring fuel prices and environmental concerns are the fundamental drivers that intensify the demand situation for titanium. From a machining viewpoint, one of the challenges companies face, is achieving high material removal rates while maintaining the form and function of the part. The ultimate aim for a machining business remains to make parts quickly. Conventional cutting speeds range from 30 to 100 m/min in the machining of Ti-6Al-4V. Milling this alloy faster however is challenging. Although titanium is becoming a material of choice, many of the same qualities that enhance titanium‟s appeal for most applications also contribute to its being one of the most difficult materials to machine. The author explored the potential for Polycrystalline diamond (PCD) inserts in high speed milling of Ti-6Al-4V, by trying to understand the fundamental causes of tool failure. The objective was to achieve an order of magnitude increase in tool life, while machining at high speed, simply by reducing some of the failure mechanisms through different cutting strategies. Tool wear is described as a thermo-mechanical high-cycle fatigue phenomenon. The capability of a higher material removal per tool life is achieved in the case of PCD inserts compared to Tungsten carbide (WC). The average surface roughness produced was relatively low. The collected chips were also analyzed. The work demonstrated progress over the performance reported in current literature. The work confirms that there is a region where a sufficiently high temperature in the cutting zone may contribute to extended tool life, provided that the tool material can withstand these extreme conditions.

Orientador: Ruis Camargo Tokimatsu / Resumo: A procura por materiais, com compatibilidade e funcionalidade biológicas, que possam melhorar a qualidade da vida humana é constante, além da busca de processos de fabricação que atendam às necessidades de manufatura de artefatos de geometria complexa. Os artefatos de aço inoxidável são utilizados por possuírem uma boa biocompatibilidade, baixo custo de produção, mas podem liberar íons como o cobalto, que é carcinogênico. O uso de Ligas de titânio é uma boa alternativa, já que possuem uma maior resistência à corrosão e boa resposta biológica, porém, seu custo é muito elevado. Considerando esses aspectos, o presente trabalho foi realizado buscando estudar, comparativamente, as características de microdureza, microdesgaste e resistência à corrosão de artefatos manufaturados para aplicações biomédicas, aproveitando as características mecânicas da liga de aço inoxidável AISI316L, usado como substrato, com as características eletroquímicas apresentadas pela liga de titânio Ti-6Al-4V, usado como material de tratamento de superfície. A sinterização direta dos metais por laser (DMLS) foi o processo de manufatura escolhido por apresentar as características de fabricação desejadas. Os ensaios realizados foram o de microdureza Vickers, ensaio de desgaste microadesivo por esfera rotativa fixa (esfera-fixa) e para o comparativo da resistência à corrosão eletroquímica foram produzidas curvas de polarização potenciodinâmicas que forneceram os seguintes parâmetros: o potencial de corrosão, a... (Resumo completo, clicar acesso eletrônico abaixo) / Mestre

Orientador: Vicente Afonso Ventrella / Resumo: O trabalho consiste em um estudo da soldagem sobre uma placa da liga de titânio ASTM (Ti-6Al-4V) de espessura 1,44 mm, utilizando o processo de soldagem à laser Nd:YAG na condição autógena, realizando alterações de parâmetros no processo de soldagem afim de alterar o aporte térmico, encontrando propriedades características como a dureza, tensão de escoamento e microestrutura do material. Os ensaios realizados para a pesquisa foram: análise macrográfica, ensaio de tração, ensaio de microdureza e caracterização microestrutural. Para revelação dos detalhes no metal de solda, foi utilizado um ataque químico com o reagente Kroll. As medidas de geometria (largura e profundidade de penetração) dos cordões de solda, assim como a presença de descontinuidades, foram realizadas através de imagens obtidas pelo microscópio estéreo Zeiss Discovery.V8. O processamento e medição das imagens foi realizado através do software "AxioVision", um software associado ao microscópio utilizado. A análise da microestrutura foi realizada através do Microscópio Óptico Neophot 21, já o ensaio de tração foi realizado através de uma Máquina Universal de Ensaios, além do ensaio de microdureza, que foi realizado na escala Vickers. As análises das propriedades mecânicas foram confrontadas com a microestrutura obtida de acordo com a variação do aporte térmico. Como resultados, foram encontradas várias características essenciais para uma boa soldagem da liga, pois a cada incremento de aporte térmico, o cordão de... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The work consists of a study of the welding on a plate of titanium alloy ASTM (Ti-6Al-4V) of thickness 1.44 mm, using the welding process Nd: YAG in the autogenous condition, making changes of parameters in the process of welding in order to change the thermal input, finding characteristic properties such as hardness, yield stress and microstructure of the material. The tests carried out for the research were: macrographic analysis, tensile test, microhardness test and microstructural characterization. To reveal the details in the weld metal, a chemical attack was used with the Kroll reagent. The measurements of the geometry (width and depth of penetration) of the weld beads, as well as the presence of discontinuities, were made through images obtained by the stereo microscope Zeiss Discovery.V8. The images were processed and measured using the "AxioVision" software, a software associated with the microscope used. The analysis of the microstructure was performed through the Optical Microscope Neophot 21, and the tensile test was performed through a Universal Testing Machine, in addition to the microhardness test, which was performed on the Vickers scale. The analysis of the mechanical properties were compared with the microstructure obtained according to the variation of the thermal input. As a result, several essential characteristics have been found for a good welding of the alloy, because with each increment of thermal input, the weld bead increases in width, depth and har... (Complete abstract click electronic access below) / Mestre

Submitted by Juliano Torteli De Godoi Zucato (jtgzucato@gmail.com) on 2018-08-15T17:17:02Z No. of bitstreams: 1 Dissertação Juliano Zucato.pdf: 6062254 bytes, checksum: c2ecd162aff92215ef89a486bafa836f (MD5) / Approved for entry into archive by Cristina Alexandra de Godoy null (cristina@adm.feis.unesp.br) on 2018-08-15T20:07:28Z (GMT) No. of bitstreams: 1 zucato_jtg_me_ilha.pdf: 6062254 bytes, checksum: c2ecd162aff92215ef89a486bafa836f (MD5) / Made available in DSpace on 2018-08-15T20:07:28Z (GMT). No. of bitstreams: 1 zucato_jtg_me_ilha.pdf: 6062254 bytes, checksum: c2ecd162aff92215ef89a486bafa836f (MD5) Previous issue date: 2018-07-03 / O trabalho consiste em um estudo da soldagem sobre uma placa da liga de titânio ASTM (Ti-6Al-4V) de espessura 1,44 mm, utilizando o processo de soldagem à laser Nd:YAG na condição autógena, realizando alterações de parâmetros no processo de soldagem afim de alterar o aporte térmico, encontrando propriedades características como a dureza, tensão de escoamento e microestrutura do material. Os ensaios realizados para a pesquisa foram: análise macrográfica, ensaio de tração, ensaio de microdureza e caracterização microestrutural. Para revelação dos detalhes no metal de solda, foi utilizado um ataque químico com o reagente Kroll. As medidas de geometria (largura e profundidade de penetração) dos cordões de solda, assim como a presença de descontinuidades, foram realizadas através de imagens obtidas pelo microscópio estéreo Zeiss Discovery.V8. O processamento e medição das imagens foi realizado através do software "AxioVision", um software associado ao microscópio utilizado. A análise da microestrutura foi realizada através do Microscópio Óptico Neophot 21, já o ensaio de tração foi realizado através de uma Máquina Universal de Ensaios, além do ensaio de microdureza, que foi realizado na escala Vickers. As análises das propriedades mecânicas foram confrontadas com a microestrutura obtida de acordo com a variação do aporte térmico. Como resultados, foram encontradas várias características essenciais para uma boa soldagem da liga, pois a cada incremento de aporte térmico, o cordão de solda aumenta em largura, profundidade e dureza, porém isto tem vantagem até determinado valor, pois conforme há o aumento do aporte térmico, a soldagem se fragiliza, pelo fato de existir vaporização do material e inclusão de poros na zona fundida. / The work consists of a study of the welding on a plate of titanium alloy ASTM (Ti-6Al-4V) of thickness 1.44 mm, using the welding process Nd: YAG in the autogenous condition, making changes of parameters in the process of welding in order to change the thermal input, finding characteristic properties such as hardness, yield stress and microstructure of the material. The tests carried out for the research were: macrographic analysis, tensile test, microhardness test and microstructural characterization. To reveal the details in the weld metal, a chemical attack was used with the Kroll reagent. The measurements of the geometry (width and depth of penetration) of the weld beads, as well as the presence of discontinuities, were made through images obtained by the stereo microscope Zeiss Discovery.V8. The images were processed and measured using the "AxioVision" software, a software associated with the microscope used. The analysis of the microstructure was performed through the Optical Microscope Neophot 21, and the tensile test was performed through a Universal Testing Machine, in addition to the microhardness test, which was performed on the Vickers scale. The analysis of the mechanical properties were compared with the microstructure obtained according to the variation of the thermal input. As a result, several essential characteristics have been found for a good welding of the alloy, because with each increment of thermal input, the weld bead increases in width, depth and hardness, however this has advantage until a certain value, since as there is increase of the contribution thermal, welding becomes fragile, due to the fact that there is vaporization of the material and inclusion of pores in the molten zone.

Titanium is one of fourth most abundant structural metal in earths soil. It is in a composition with other elements, forming titanium alloys. These alloys are used in many different areas, such as medical, energy and sports, but is most commonly used in aerospace applications. Titanium alloys have different solid phases, α, α+β and β depending on temperature and the amount of α and β-stabilizers.When machining titanium alloys, one of the most important factors to control is the temperature in the cutting zone. The built-up heat in the cutting edge of the tool, are connected to titanium alloys low thermal conductivity and high heat capacity, which means that the alloy has low heat conduction from the cutting zone. The temperature is strongly depending on the cutting speed, which is the relative speed difference between the cutting tool and the workpiece. Many studies and research work have been conducted surrounding this fact, focusing on the physical and chemical quantities, to model tool wear progression and how this affects the tool life and the metal removal. These models are often implemented and analyzed in finite element software providing detailed but time-consuming solutions.The focus for this work have been on developing a suitable tool life expectancy model, using design of experiments in combination with metamodeling to establish a model connecting cutting parameters and measured responses in terms of tool life, from a conducted milling experiment. This models where supposed to provide a platform for customer recommendation and cutting data optimization to secure reliable machining operations. The study was limited to focus on the common α+β titanium alloy 6Al-4V. The outcome and conclusion for this study, is that the tool life is strongly connected to the choice of cutting speed and the radial width of cut and that these parameters can be predicted by the two models that have been develop in this project. The models ensure the highest possible metal removal rate, to selected parameters.

The main purpose of this thesis is to investigate the ductility and application of titanium alloys, like titanium 6Al-4V, when used in aerospace fasteners compared to more conventional stainless steel aerospace fasteners such as A286. There have been concerns raised about the safe usability of titanium 6-4 in the aerospace industry due to its lack of strain hardening. However, there is a lack of data pertaining to this concern of safe usage which this thesis aims to address. Tensile tests were conducted to find the ductility indexes of these fasteners which quantify the amount of plastic to elastic elongation. From the tests conducted it was found that the two materials yield and tensile strengths were very similar, though the ductility index of A286 is on average ten times greater than that of titanium 6-4. This thesis includes joint diagram examples that analyze typical joints using both materials. It was found from joint diagram examples that the lower ductility index of the titanium alloy will only be detrimental to use at higher preloads. However, the titanium alloy can be used safely in place of A286 in most loading situations just with narrower safety margins in these controlled examples.

Eurocoating, Italy, is a company that works in the biomedical sector. They have for a long time created prostheses from CAD files achieved from customers, and now they want to build their own expertise about the design. The thesis work was a part of a three year long collaborative research project between Eurocoating and University of Trento that was aiming to investigate the prostheses with open-porous surface and trabecular structure, created by Selective Laser Melting. The purpose of the thesis was to investigate and characterize 30 different trabecular structures of Ti-6Al-4V, fabricated by Selective Laser Melting. That includes investigation the effect on the morphology and porosity fraction caused by the manufacturing and the effect on mechanical and physical properties due to the different characterizations of the structures. The thesis work had its foundation in literature studies to receive deep knowledge about the subject. Practical tests were performed to investigate mechanical behaviour under compressive and tensile loading, static friction and wear resistance. The findings from these tests were compared to the porosity fraction and the morphological characterizations. The result stated that the porosity fraction was lower than the designed porosity, and that is was strongly influenced by size of the voids and struts. The strut thickness was higher than the design values, especially on the lateral surface, while the voids size were approximately as designed. Result from the compression test showed a trend of decreasing stiffness and strength with increasing porosity fraction. Also structures with same porosity fraction could have a wide range in mechanical properties which indicates high dependence on the morphological geometry i.e. pore size and shape, strut size and pore distribution. Comparisons between tensile and compression behaviour stated that the structures had a lower strength but a significant higher stiffness in tensile load. All structures from the wear test showed a good resistance while the results from the friction test needs further investigation to be fully understood. The physical and mechanical properties of the trabecular structures was found to be close to those of cortical and trabecular bone in porosity, stiffness and strength. There is a range of variations leading to possibilities to adopt the application depending on customer. Thus, these can be considered as promising structures used biomedical application to optimize osseointegration and secondary long term fixation.

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