In the present study, production of titanium and Ti6Al4V alloy foams has been investigated using powder metallurgical space holder technique in which magnesium powder were utilized to generate porosities in the range 30 to 90 vol. %. Also, sintering of titanium and Ti-6Al-4V alloy powders in loose and compacted condition at various temperatures (850-1250oC) and compaction pressures (120-1125 MPa), respectively, were investigated to elucidate the structure and mechanical properties of the porous cell walls present due to partial sintering of powders in the specimens prepared by space holder technique. In addition, microstructure and mechanical response of the porous alloys were compared with the furnace cooled bulk samples of Ti-6Al-4V-ELI alloy subsequent to betatizing. It has been observed that the magnesium also acts as a deoxidizer during foaming experiments, and its content and removal temperature is critical in determining the sample collapse. Stress-strain curves of the foams exhibited a linear elastic region / a long plateau stage / and a densification stage. Whereas, curves of loose powder sintered samples were similar to that of bulk alloy. Shearing failure in foam samples occurred as series of deformation bands formed in the direction normal to the applied load and cell collapsing occured in discrete bands. Average neck size of samples sintered in loose or compacted condition were found to be different even when they had the same porosity, and the strength was observed to change linearly with the square of neck size ratio. The relation between mechanical properties of the foam and its relative density, which is calculated considering the micro porous cell wall, was observed to obey power law. The proportionality constant and the exponent reflect the structure and properties of cell walls and edges and macro pore character.

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The usage of titanium alloys in many industries has increased significantly over the years due to their superior properties. However, they are extremely difficult to machine because of their distinctive characteristics such as their high temperature strength, low thermal conductivity, and high chemical affinity for tool materials. Hence, despite their increased usage, they are still expensive to machine when compared to other metals. The current research aims to address the machinability issues of titanium alloys by developing novel compositions of a new generation of self-adaptive Physical Vapor Deposition (PVD) coatings that function by forming beneficial tribo-films through their interaction with the environment. These tribo-films form during cutting and provide enhanced lubricity, hardness, strength, and thermal barrier characteristics to the cutting tool. It was found that during Ti6Al4V machining, significant BUE and crater wear formation occurs; however, one is dominant over the other depending on the cutting conditions. Therefore, the coatings investigated were designed by taking into consideration the dominant tool wear mechanisms and the complex tribological phenomena that occur in the cutting zone. The current research investigated monolayer TiB2 and CrN self-adaptive PVD coatings for the rough (cutting speed - 45 m/min, feed -0.15 mm/rev, and depth of cut – 2 mm) and finish (cutting speed - 150 m/min, feed -0.1225 mm/rev, and depth of cut – 0.25 mm) turning of Ti6Al4V alloy. Detailed experimental studies were performed to study the effectiveness of the coatings during machining. Micro-mechanical characteristics of the coatings were also studied to understand how coating properties affect the coatings performance in machining and tribo-film formation. The results obtained show that both the TiB2 and CrN coatings significantly improve tool performance during the rough turning of Ti6Al4V alloy compared to the current industrial standard, which is due to certain micro-mechanical coating properties and the beneficial tribo-films formed. A coating of CrN coating was found to increase tool life during finish turning. It was also established that for machining applications where intensive adhesive interaction occurs at the tool-chip interface, coatings with lower hardness values perform significantly better than harder ones. / Thesis / Doctor of Philosophy (PhD) / Titanium alloys are increasingly becoming the material of choice for many industrial applications due to their superior properties. However, they are very difficult to machine since they have high chemical affinity towards tool materials, low thermal conductivity, and high temperature strength. These properties cause rapid failure of the tool. The objective of the current research is to address machinability issues during Ti6Al4V machining and improve tool performance. One effective strategy to minimize tool wear is to apply self-adaptive PVD tool coatings that can form beneficial tribo-films through their interaction with the environment and provide enhanced lubricity, hardness, strength, and thermal barrier characteristics to the cutting tool. In the current research, two self-adaptive PVD coatings were developed that offset the dominant tool wear mechanisms prevalent during the rough and finish turning of Ti6Al4V alloy and reduced the tool wear rate by more than 60% compared to the current industrial standard.

>Magister Scientiae - MSc / Hydrogen has high energy density and it is regarded as the future energy carrier. Hydrogen can be stored as a gas in high-pressure cylinders, as a liquid in cryogenic tanks and as a solid in metal hydrides. The storage of hydrogen in gas and liquid form has many limitations. Light metal hydrides show high energy density and are a promising and more practical mode of hydrogen storage. In particular, titanium and its alloys are promising metal hydrides for hydrogen storage due to their high affinity to hydrogen. The aim of this study is to investigate the effect of thermal annealing on hydrogen storage capacity of Ti-Pd multilayer systems. Ti-Pd multilayer films were prepared on CP-Ti (commercial pure Ti) and Ti6Al4V substrates using an electron beam evaporator equipped with a thickness monitor. The sequential deposition of layers Pd(50nm)/Ti(25nm)/Pd(50nm) was done at a constant deposition rate of 0.6 Å/s. The first batch of samples were thermally annealed at 550 °C in vacuum for two hours, the second batch of samples were annealed at 550 oC under H2(15%)/Ar(85%) gas mixture for two hours and the third series of samples was annealed under pure H2 gas at 550 oC for one hour. SEM showed relatively homogeneous and smooth topography of surfaces in as-deposited samples, while a rough textured surface was observed in both samples annealed under vacuum and under H2/Ar gas mixture. The samples annealed under pure H2 gas did not show any sign of crystallites grow but instead a relatively smooth surface with sign of etching. XRD revealed structural transformation as evidenced by the presence of PdTi2 phase in samples annealed under vacuum; in samples annealed under the gas mixture Pd2Ti was noted in addition to TiH2 and TiO2. While the TiH2 phase is an indication of hydrogen absorption, the TiPd2 phase suggests intermixing of the deposited layers and the presence of TiO2 is evidence of oxidation. The samples annealed under pure H2 gas showed only TiH2 with no trace of structural transformation. RBS confirmed the intermixing of layers in the samples annealed under vacuum and H2(15%)/Ar(85%) gas mixture, while samples annealed under pure H2 gas did not show any intermixing of layers. ERDA revealed an average H content of ~ 3.5 at.% in CP-Ti and ~6.2 at.% in Ti6Al4V for samples annealed under H2(15%)/Ar(85%) gas mixture. We recorded an hydrogen content of ~19.5 at.% in CP-Ti annealed under pure H2 while ~25.5 at.% was found in Ti6Al4V annealed under the same conditions. When the thickness of the Pd catalyst layers was increased to 100 nm (i.e. Pd (100 nm)/Ti (25 nm)/Pd (100 nm)), only ~ 12.5 at.% and 11.2 at. % hydrogen content was recorded in samples prepared on CP-Ti and Ti6Al4V alloy respectively, both annealed under pure hydrogen for one hour as above.