Dissertation submitted in fulfilment of the requirements for the degree Master of Technology: Mechanical Engineering in the Faculty of Engineering at the Cape Peninsula University of Technology 2014 / The research described in this dissertation investigates the feasibility of casting inlet valves for an internal combustion engine using Ti6Al4V alloy. The engine valves operate in an extreme environment under high thermal cycles – this requires a material that can withstand such exposures. Ti6Al4V is the most common titanium alloy with high temperature creep and fatigue resistant behaviour, however, it is not all positive. Ti6Al4V alloy also yields many difficulties with respect to processing especially when the material is cast. It is therefore important to gain a thorough understanding of the pouring and solidification characteristics of this material. The main focus of this work was to investigate and optimise feeding and geometrical parameters to produce valves that are free from defects, especially porosity. An in depth analyses of the parameters that influenced the casting quality was performed, and it was found that casting orientation, inlet feeder geometry, initial and boundary conditions all played a vital role in the final results. These parameters were individually investigated by performing detailed numerical simulations using leading simulation software for each of these cases. For each case, a minimum of ten simulations was performed to accurately determine the effect of the alteration on casting soundness and quality. Furthermore, the relationships (if any) were observed and used in subsequent optimised simulations of an entire investment casting tree. The change of geometric orientation and inlet feeder diameter and angle showed distinct relationships with occurrence of porosity. On the other hand, alteration in the pouring parameters, such as temperature and time, had negligible effect on occurrence or position of porosity in the valve. It was found that investigating individual parameters of simple geometry and then utilising these best-fit results in complex geometry yielded beneficial results that would otherwise not be attainable.

Zinc-titanium alloys (0.07-0.6 wt.%Ti.) in the form of compacted powder and chill castings have been extruded at temperatures between 150°C and 350°C. The mechanical properties of these alloys have been studied as a function of temperature, strain rate, grain size and intermetallic (Zn₁₅Ti) distribution. Due to a high value of "k" in the Hall-Petch relationship, maximum strengthening is obtained by a reduction in grain size. However because of an increasing amount of grain boundary shear, this potential is not realized. The operation of dynamic recovery mechanisms at 20°C and higher also results in limitations upon the development of high strength. The use of powder metallurgical techniques gives rise to the formation of intermetallic distributions which inhibit these processes and results in high strength (>60,000 p.s.i.) and low strain rate sensitivity (m ∼ 0.02). The mechanical properties are not a function of initial powder size. The properties obtained using chill castings do not reach these levels due to the difficulty associated with forming a fine second phase on solidification. Such a distribution is required to obtain a small stable grain size during subsequent extrusion. To satisfy compatibility requirements deformation modes other than the two supplied by basal slip must be invoked. High strengths are observed when grain boundary shear and migration are inhibited by the distribution of the second phase or by orientation effects. Under such conditions, non basal slip and basal slip are the operative deformation mechanisms. Significantly lower strengths result if grain boundary shear and basal slip satisfy the conditions necessary for ductile behaviour. The strain rate sensitivity parameter at 20°C lies in the range 0.02-0.07. Varying amounts of grain boundary shear occur, nevertheless deformation is slip controlled. Increased strain rate sensitivities are observed at high temperatures, but failure by cavitation limits ductility. The strain rate sensitivity is not a function of titanium concentration. Under constant fabrication conditions the strength generally increases with increased Zn₁₅Ti content. The thermal stability of the intermetallic distribution prescribes the fabrication conditions which must be used to develop high strength, and the temperature to which the mechanical properties can be retained. The high strength microstructures appear to be stable up to at least 150°C for short periods of time. / Applied Science, Faculty of / Materials Engineering, Department of / Graduate

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Due to its excellent biocompatibility and mechanical properties, Ti-6Al-4V alloy has been extensively used in the medical field, especially as a material for hard tissue replacement. Owing to the unique shape memory and superelastic properties, NiTi shape memory alloy (SMA, with 50.8 at.% of Ni) has been investigated for load-bearing applications in orthopedics and dentistry. Since the longevity of current metal implants is approximately 10 to 15 years, many patients need to have revision surgeries in their lifetime. Therefore, there is great interest in the long-term stability, biocompatibility, bioactivity and other properties of Ti-6Al-4V and NiTi SMA implants. Implant-associated infections also pose serious threat to the success of metal implants. The goal of this project was to investigate several low-temperature surface modification techniques, including anodization and electrochemical deposition, and formulate coatings for potential clinical applications. Accordingly, several types of coatings were synthesized on Ti-6Al-4V and NiTi SMA substrates. Various aspects of the coatings, such as morphology, chemical composition, crystallinity, phase and bioactivity, were analyzed. Firstly, a systematic study on the formation of titania nanotubes on Ti-6Al-4V by anodization was performed. Anodizing voltage and time were varied for comparisons. A dense and compact titania nanotube layer was synthesized on Ti-6Al-4V by anodizing at 25 V for 20 min. The titania nanotubes formed were rutile. After annealing at 500oC for 1 h, the titania nanotubes became anatase. The anatase phase exhibited better wettability than the rutile phase. Secondly, dense and compact apatite coatings were formed on NiTi SMA samples through electrochemical deposition using mainly double-strength simulated body fluid (2SBF) as the electrolyte. The deposition conditions were varied and apatite coating characteristics studied. With the inclusion of collagen molecules (0.1 mg/ml) in the electrolyte (2SBFC), apatite/collagen composite coatings were fabricated. Collagen fibrils were not only observed on the surface of composite coatings but also were embedded inside in the coatings and at the coating-substrate interface. Results obtained from transmission electron microscopic and X-ray diffraction analyses showed that the apatite crystals in apatite coatings and apatite/collagen composite coatings were calcium-deficient carbonated hydroxyapatite. Apatite/collagen composite coatings exhibited excellent hydrophilicity, whereas apatite coatings displayed hydrophobic surfaces. Finally, gentamicin-loaded, tobramycin-loaded, and vancomycin-loaded apatite coatings and apatite/collagen composite coatings were synthesized on NiTi SMA samples through electrochemical deposition using different drug concentrations in the electrolytes. A comparative study of apatite coatings and apatite/collagen composite coatings as drug delivery vehicles were conducted. Different aspects of antibiotic-loaded coatings (surface characteristics, chemical composition, wettability, etc.) and in vitro release behaviour were investigated. The antibiotics were physically embedded in coatings during coating formation. Upon sample soaking in phosphate-buffered saline (PBS), the release profiles established for antibiotic-loaded coatings demonstrated different levels of initial burst release and subsequent steady release characteristics. Apatite coatings and apatite/collagen coatings displayed preferential incorporation of specific antibiotics. For instance, apatite/collagen coatings showed better vancomycin incorporation than apatite coatings and the incorporation of vancomycin was better than tobramycin for apatite/collagen coatings. Apatite coatings demonstrated better tobramycin incorporation than apatite/collagen composite coatings. / published_or_final_version / Mechanical Engineering / Master / Master of Philosophy

Thesis (Ph.D.)--University of Western Australia, 2005.

M.Ing. (Mechanical Engineering) / High strength alloys such as titanium are widely used within applications that require specific material properties. These include high strength, high temperature as well as low weight applications. Thus a need arises to investigate the fundamental to understand the mechanics of how these materials are machined. Titanium alloys are known for the difficulties that arise during the machining thereof. Complexities arise due to its inherent material properties, the most important property being the retention of strength at high temperatures. In addition to maintaining its strength, it becomes highly chemically reactive with other materials at increased temperatures. All these factors contribute to extreme temperatures at the tool chip interface contributing to increased tool wear and shortened tool life. The aim of the research is to investigate the effect of machining on various cutting process parameters including cutting force, temperature, tool wear and surface finish for grade 2 and grade 5 titanium alloys during high speed turning. Grade 2 titanium is a commercially grade with lower mechanical properties, while Grade 5 is titanium alloy with substantially higher mechanical properties and is the most widely used titanium alloy. In addition an experimental setup was developed and verified to conduct fundamental research on the high speed machining of titanium alloys. A literature review was concluded with focus on the machining of titanium alloys. This was followed by the development of the experimental setup, measurement and compilation of data. The data was compiled into graphs and compared with the current research available. The research found that for the cuts performed, that cutting forces are independent of cooling applied and that no substantial variation was noted between the two grades. When temperatures were evaluated, dramatic drops in temperature were noted when coolant was applied. As temperatures increased, specifically during un-cooled cutting, the inserts deteriorated having an effect on the quality of the surfaces obtained. When coolant was applied, substantial temperature drops were achieved, improving tool life and directly improving surface finishes. The best surface finish was achieved for higher cutting speeds as and lower feed rates. This phenomenon was found for both grades of titanium evaluated. The largest amount of tool wear was noted for the highest cutting speeds, with increased values noted for Grade 5 in comparison with Grade 2. This phenomenon is noted for crater as well as flank wear.

M.Ing. / Grade 4 titanium is a commercially pure grade titanium alloy extensively used in various industries including the chemical industry and more recently in the biomedical industry. Grade 4 has found a niche as a biomedical material for production of components such as orthopaedic and dental implants. Its physical properties such as high corrosion resistance, low thermal conductivity and high strength make it suitable for these applications. These properties also make it hard-to-machine similar to the other grades of titanium alloys and other metals such as nickel based alloys. During machining of titanium, elevated temperatures are generated at the tool-workpiece interface due to its low thermal conductivity. Its high strength is also maintained at these high temperatures. These tend to impair the cutting tool affecting its machinability. Various investigations on other grades of titanium and other hard-to-machine materials have shown that machining at high cutting speeds may improve certain aspects of their machinability. High speed machining (HSM) is used to improve productivity in the machining process and to therefore lower manufacturing costs. HSM may, however, change the surface integrity of the machined material. Surface integrity refers to the properties of the surface and sub-surface of a machined component which may be quite different from the substrate. The properties of the surface and sub-surface of a component may have a marked effect on the functional behaviour of a machined component. Fatigue life and wear are examples of properties that may be significantly influenced by a change in the surface integrity. Surface integrity may include the topography, the metallurgy and various other mechanical properties. It is evaluated by examination of surface integrity indicators. In this investigation the three main surface integrity indicators are examined. These are surface roughness, sub-surface hardness and residual stress. White layer thickness and chip morphology were also observed as results of the machining process used. The effect of HSM on the surface integrity of grade 4 is largely unknown. This investigation therefore aims to address this limitation by conducting an experimental investigation on the effect of HSM on selected surface integrity indicators for grade 4. Two forged bars of grade 4 alloy were machined using a CNC lathe at two depths of cut, 0.2mm and 1mm. Each bar was machined at varying cutting speeds ranging from 70m/min to 290m/min at intervals of approximately 20m/min. Machined samples were prepared from these cutting speeds and depths of cut. The three surface integrity indicators were then evaluated with respect to the cutting speed and depth of cut (DoC). iv Results show that a combination of intermediate cutting speeds and low DoC may have desirable effects on the surface integrity of grade 4. Highest compressive stresses were obtained when machining with these conditions. High compressive stresses are favourable in cases where the fatigue life of a material is an important factor in the functionality of a component. Subsurface hardening was noticed at 0.2mm DoC, with no subsurface softening at all cutting speeds. Surface hardness higher than the bulk hardness tends to improve the wear resistance of the machined material. Though surface roughness values for all depths of cut were below the standard fine finish of 1.6μm, roughness values of samples machined at 0.2mm DoC continued to decrease with increase in cutting speed. Low surface roughness values may also influence the improvement of fatigue life of the machined components. These machining conditions, (intermediate cutting speeds and low DoC), seem to have promoted mechanically dominated deformation during machining rather than thermal dominated deformation. Thermal dominated deformation was prominent on titanium machined at DoC of 1mm.

M.Eng. (Mechanical Engineering) / High speed machining (HSM) has the potential to greatly increase productivity and to lower manufacturing costs if workpiece surface integrity can be controlled. The surface fmish of a biomaterial is vitally important for proper implant functioning, and is the focus of this study. Grade 4 titanium was turned on a lathe with cutting speeds increasing from the conventional to the high speed range. The surface finish was assessed using profilometry, atomic force microscopy, and contact angle measurement. The ability of the material to bond directly with bone was predicted by cell adhesion studies. Results indicate that there is a general relationship between cutting speed, surface roughness, contact angle, and cell adhesion. Turning grade 4 titanium at cutting speeds between 150m/min and 200m/min may provide an optimal surface for osseointegration.

One of the central questions of materials science is which crystallographic structure a certain alloy or compound will adopt as a function of elemental composition, pressure and temperature. This question can be traced back all the way from the Bronze Age via the first steel makers of the Middle Ages and the metallurgists of the 19th century to the present day. Experiences drawn from centuries of alloy making have given rise to well-established rules of thumb for alloy development and detailed phase diagrams for equilibrium conditions. However, a rigorous theory for single-phase alloys out of equilibrium is less well established. This study employs state-of-the-art electronic structure calculations based on density functional theory to tackle this problem. This method employs a reformulation of quantum mechanics to solve the many-body Schrodinger equation that describes the system. In our case, the system is a titanium alloy, where titanium is substitutionally alloyed with elements such as aluminium, chromium, vanadium and molybdenum. We find that chromium and vanadium stabilise the β phase, while scandium destabilises it. The strength of this effect is directly proportional to the additional d-electrons present in the alloying element. The effect appears to be additive, and the positional effects of the alloying atoms appear to be small. Using the results from the calculations we can construct new phase diagrams and equations of state for these alloys. This gives us a theoretical confirmation for established rules of thumb and provides us with new insights when constructing new alloys.