Laser Welding of Ti6Al4V Titanium Alloy in Air and a Water Medium

Ti6Al4V titanium alloys are widely used in a variety of scientific and industrial fields. Laser beam welding is one of the most effective techniques for the joining of titanium plates. The main objective of this study was to investigate the influence of the most important laser parameters on welding performance of titanium alloy in two different physical environments such as air and water (i.e., serum) media. Specifically, the laser beam welding of 2 mm thick Ti6Al4V samples was applied using an Nd:YAG laser in open-air welding using argon as a shielding gas, and in wet welding using a serum environment. The deepest penetration was achieved at −3 mm focal position with 11 J of laser energy in both investigated media (i.e., air and serum). The maximum hardness (1130 HV) was achieved for the focal position of −4 mm in serum medium while it was 795 HV for a focal position of −5 mm in air medium. The minimum (1200 μm and 800 μm) and maximum (1960 μm and 1900 μm) weld widths were observed for air and serum medium, respectively. After the welding process, martensite, massif martensite, and transformed martensite were observed in the microstructure of Ti6Al4V. To the best of our knowledge, the underwater wet welding of titanium alloy was carried out and reported for the first time in this study.     

The Influence of ZnO Oxide Layer on the Physicochemical Behavior of Ti6Al4V Titanium Alloy

Titanium and its alloys are characterized by high biocompatibility and good corrosion resistance as a result of the ability to form a TiO₂ oxide layer. However, based on literature data it can be concluded that titanium degradation products, in the form of titanium particles, metal-protein groups, oxides and ions, may cause allergic, inflammatory reactions and bone resorption. The corrosion process of Ti6Al4V in the human body environment may be intensified by a decreased pH and concentration of chloride compounds. The purpose of this article was to analyze the corrosion resistance of the Ti6Al4V alloy, obtained by the selective laser melting method in a corrosion solution of neutral pH and in a solution simulating peri-implant inflammatory conditions. Additionally, the influence of zinc oxide deposited by the atomic layer deposition method on the improvement of the physicochemical behavior of the Ti6Al4V alloy was analyzed. In order to characterize the ZnO layer, tests of chemical and phase composition as well as surface morphology investigation were performed. As part of the assessment of the physicochemical properties of the uncoated samples and those with the ZnO layer, tests of wetting angle, pitting corrosion and impedance corrosion were carried out. The number of ions released after the potentiodynamic test were measured using the inductively coupled plasma atomic emission spectrometry (ICP–AES) method. It can be concluded that samples after surface modification (with the ZnO layer) were characterized by favorable physicochemical properties and had higher corrosion resistance.     

Study on Characteristics for Reaming Titanium Alloy Ti6Al4V with Two Kinds of Cemented-Carbide Groove Reamers

Titanium alloys have been extensively used in practical machining owing to their outstanding mechanical properties, high specific strength and low thermal deformation. In this study, the cutting experiments are carried out on Ti6Al4V material with right-hand and straight cemented-carbide groove reamers. The experimental results show that the cutting force with the right-hand reamer is smaller compared to straight groove reamer due to the groove structure. The main tool wear forms are micro-chipping, adhesive wear, abrasive wear, and coating falling off on the right-hand reamer, while there is a built-up edge and serious damage failure on the cutting edge of the straight groove reamer. Notch wear and pitting on the surface of the hole wall are mainly caused by chip adhesion and tool wear. The surface-roughness value is the lowest as the cutting speed is 60 m/min and the feed rate is 0.4 mm/rev. The holes machined by the right-hand reamer have a low hole diameter deviation with various cutting parameters. The geometric accuracy of cylindricity is higher as the feed rate is 0.4 mm/rev and the cutting speed is 40 m/min for both kinds of reamers, and the cylindricity is better with the right-hand reamer.     

Strength Properties of a Porous Titanium Alloy Ti6Al4V with Diamond Structure Obtained by Laser Power Bed Fusion (LPBF)

This paper presents the results of experimental research on the strength properties of porous structures with different degrees of density manufactured of Ti6Al4V titanium alloy by Laser Power Bed Fusion. In the experiment, samples with diamond structure of porosity: 34%, 50%, 73% and 81% were used, as well as samples with near-zero porosity. Monotonic tensile tests were carried out to determine the effective values of axial modulus of elasticity, ultimate tensile strength, offset yield strength, ultimate elongation and Poisson ratio for titanium alloys with different porosities. The paper also proposes relationships that can be easily used to estimate the strength and rigidity of a porous material manufactured by 3D printing. They were obtained by the approximation of two quotients. The first one refers to the relationship between the tensile strength of a material with a defined porosity to the strength of full-filled material. The second similarly determines the change in the value of the axial modulus of elasticity. The analysis of microscopic observations of fracture surfaces and also microtomography visualization of the material structure are also presented.     

Manufacturing and Characterization of Ti6Al4V Lattice Components Manufactured by Selective Laser Melting

The paper investigates the fabrication of Selective Laser Melting (SLM) titanium alloy Ti6Al4V micro-lattice structures for the production of lightweight components. Specifically, the pillar textile unit cell is used as base lattice structure and alternative lattice topologies including reinforcing vertical bars are also considered. Detailed characterizations of dimensional accuracy, surface roughness, and micro-hardness are performed. In addition, compression tests are carried out in order to evaluate the mechanical strength and the energy absorbed per unit mass of the lattice truss specimens made by SLM. The built structures have a relative density ranging between 0.2234 and 0.5822. An optimization procedure is implemented via the method of Taguchi to identify the optimal geometric configuration which maximizes peak strength and energy absorbed per unit mass.     

Numerical Modeling and Analysis of Ti6Al4V Alloy Chip for Biomedical Applications

The influence of cutting forces during the machining of titanium alloys has attained prime attention in selecting the optimal cutting conditions to improve the surface integrity of medical implants and biomedical devices. So far, it has not been easy to explain the chip morphology of Ti6Al4V and the thermo-mechanical interactions involved during the cutting process. This paper investigates the chip configuration of the Ti6Al4V alloy under dry milling conditions at a macro and micro scale by employing the Johnson-Cook material damage model. 2D modeling, numerical milling simulations, and post-processing were conducted using the Abaqus/Explicit commercial software. The uncut chip geometry was modeled with variable thicknesses to accomplish the macro to micro-scale cutting by adapting a trochoidal path. Numerical results, predicted for the cutting reaction forces and shearing zone temperatures, were found in close approximation to experimental ones with minor deviations. Further analyses evaluated the influence of cutting speeds and contact friction coefficients over the chip flow stress, equivalent plastic strain, and chip morphology. The methodology developed can be implemented in resolving the industrial problems in the biomedical sector for predicting the chip morphology of the Ti6Al4V alloy, fracture mechanisms of hard-to-cut materials, and the effects of different cutting parameters on workpiece integrity.     

Tribological Properties of Ti6Al4V Alloy Composite Texture Fabricated by Ultrasonic Strengthening Grinding and Laser Processing

The Ti6Al4V alloy has been widely used in aerospace equipment and medical devices. However, the poor wear resistance of the Ti6Al4V alloy hinders its further engineering application. In this study, the ultrasonic strengthening grinding process (USGP) and laser texturing process were employed to enhance the wear resistance of Ti6Al4V alloy. The frictional behavior of all samples was determined via a ball-on-disc friction and wear tester under dry conditions. The worn surface morphology, cross-sectional hardness, surface roughness, and microstructure were analyzed. The results demonstrated that the USGP induced high hardness, high dislocation density, and grain refinement, as well as improvements in the wear resistance of Ti6Al4V. Moreover, laser texture could enhance the capacity to capture wear debris and reduce wear probability. When combining the USGP and laser texturing process for the surface treatment of Ti6Al4V alloy, the lowest and most stable friction coefficients were obtained, as well as the best wear resistance. Compared to the polished sample, the steady stage friction coefficient of the sample treated by USGP and laser texturing process was remarkably decreased by 58%. This work demonstrates that combining the USGP and laser texturing process could be a promising solution for improving the wear resistance properties of Ti6Al4V alloy, which makes it more suitable for various engineering applications.     

Fundamental Investigation into Tool Wear and Surface Quality in High-Speed Machining of Ti6Al4V Alloy

This paper reports a fundamental investigation consisting of systematic trials into the response of Ti6Al4V alloy to high-speed machining using carbide inserts. It is a useful extension to work previously published, and aims at assessing the impact of the process parameters, depth of cut, cutting speed and feed rate in addition to cutting length, and their interrelations, on observed crater and flank wear and roughness of the machined surface. The results showed that abrasion was the most important flank wear mechanism at high speed. It also showed that increased cutting length accelerated crater wear more than exhibited flank wear and had considerable effect on surface roughness. In particular, crater wear increased by over 150% (on average), and flank wear increased by 40% (on average) when increasing cutting length from 40 to 120 mm. However, cutting the same length increased surface roughness by 50%, which helps explain how progression of tool wear leads to deteriorated surface quality. ANOVA was used to perform statistical analyses of the measured data and revealed that cutting length and depth of cut had the greatest effect on both crater and flank wear of the cutting tool. These results confirm that high-speed machining of Ti6Al4V alloy is a reliable process, with cutting speed identified as having a relatively small influence on the tool wear and resultant roughness of the machined surface relative to other parameters.     

Constitutive Model Parameter Identification Based on Optimization Method and Formability Analysis for Ti6Al4V Alloy

Titanium alloy is widely applied in aerospace, medical, shipping and other fields due to its high specific strength and low density. The purpose of this study was to analyze the formability of Ti6Al4V alloys at elevated temperatures. An accurate constitutive model is the basic condition for accurately simulating the plastic forming of materials, and it is an important basis for optimizing the parameters of the hot forging forming process. In this study, the optimization algorithm was used to accurately identify the high-temperature constitutive model parameters of Ti6Al4V titanium alloy, and the hot working diagram was established to optimize the hot forming process parameters. The optimal forming conditions of Ti6Al4V titanium alloy are given. Ti6Al4V alloy was subjected to high-temperature compression tests at 800–1000 °C and at strain rates of 0.01–5 s⁻¹ on a Gleeble-1500D thermal/mechanical simulation machine. Each parameter of the Hansel–Spittel constitutive model was taken as an independent variable, and the accumulated error between the stress calculated by the constitutive model and the stress obtained by experimentation was used as an objective function. Based on response surface methodology, an inverse optimization method for identifying the parameters of the high-temperature constitutive model of Ti6Al4V alloy is proposed in this paper. An orthogonal test design was adopted to obtain sample point data, and a third-order response surface approximate model was established. The genetic algorithm (GA) was applied to reversely optimize the parameters of the constitutive model. To verify the accuracy of the optimized constitutive model, the average absolute relative error (AARE) and correlation coefficient (R) were used to evaluate the reliability of optimized constitutive model. The R value of the model was 0.999, and the AARE value was 0.048, respectively, indicating that the established high-temperature constitutive model for Ti6Al4V alloy has good calculation accuracy. The flow stress behavior of the material could be accurately delineated. Meanwhile, in order to study the formability of Ti6Al4V alloy, the hot processing map of the alloy, based on a dynamic material model, was established in this paper. The optimum hot working domains of the Ti6Al4V alloy were determined within 840–920 °C/0.01–0.049 s⁻¹ and 940–980 °C/0.11–1.65 s⁻¹; the hot processing map was verified in combination with the microstructure, and the fine and equiaxed grains and a large amount of β phase could be found at 850 °C/0.01 s⁻¹.     

Corrosion Resistance of Selective Laser Melted Ti6Al4V3Cu Alloy Produced Using Pre-Alloyed and Mixed Powder

Metallic elemental powder mixture and pre-alloyed metallic powder are both frequently used powder feedstock in the additive manufacturing process. However, little research has been conducted to compare the corrosion behavior of selective laser melting (SLM) alloys, fabricated by pre-alloyed metallic powder and mixed metallic powder. Hence, it is important to investigate the corrosion behavior of SLMed alloys, as well as the corresponding cast ingot, with the aim to better understand the feasibility of designing new materials. In this work, the SLM-produced Ti6Al4V3Cu alloys were manufactured using a metallic elemental powder mixture and pre-alloyed metallic powder, respectively. The corrosion behavior of the different Ti6Al4V3Cu alloys was investigated in following electrochemical tests and ion release measurements. The results showed that the Ti6Al4V3Cu alloy prepared by pre-alloyed metallic powder showed better corrosion resistance than that produced from mixed metallic powder. Moreover, the SLM-produced Ti6Al4V3Cu alloys performed significantly better in corrosion resistance than the cast Ti6Al4V3Cu. The results are expected to achieve a better understanding of the feasibility of designing new materials using mixed powders, contributing to reducing development costs and cycles.     

Investigation of the Wear Performance of TiB2 Coated Cutting Tools during the Machining of Ti6Al4V Alloy

The machining of Ti6Al4V alloy, especially at low cutting speeds, is associated with strong Built-Up Edge (BUE) formation. The PVD coatings applied on cutting tools to machine such materials must have the necessary combination of properties to address such an underlying wear mechanism. The present work investigates and shows that TiB₂ PVD coating can be designed to have certain mechanical properties and tribological characteristics that improve machining in cases where BUE formation is observed. Three TiB₂ coatings were studied: one low hardness coating and two high hardness coatings with varied coating thicknesses. Wear performances for the various TiB₂ coated carbide tools were evaluated while rough turning Ti6Al4V. Tool wear characteristics were evaluated using tool life studies and the 3D wear volume measurements of the worn surface. Chip morphology analyses were done to assess the in-situ tribological performance of the coatings. The micro-mechanical properties of the coatings were also studied in detail to co-relate with the coatings’ performances. The results obtained show that during the rough turning of Ti6Al4V alloy with intensive BUE formation, the harder TiB₂ coatings performed worse, with coating delamination on the rake surface under operation, whereas the softer version of the coating exhibited significantly better tool life without significant coating failure.     

Preclinical In Vitro Assessment of Submicron-Scale Laser Surface Texturing on Ti6Al4V

Loosening of orthodontic and orthopedic implants is a critical and common clinical problem. To minimize the numbers of revision surgeries due to peri-implant inflammation or insufficient osseointegration, developments of new implant manufacturing strategies are indicated. Ultrafast laser surface texturing is a promising contact-free technology to modify the physicochemical properties of surfaces toward an anti-infectious functionalization. This work aims to texture Ti6Al4V surfaces with ultraviolet (UV) and green (GR) radiation for the manufacturing of laser-induced periodic surface structures (LIPSS). The assessment of these surface modifications addresses key aspects of topography, morphology and chemical composition. Human primary mesenchymal stromal cells (hMSCs) were cultured on laser-textured and polished Ti6Al4V to characterize the surfaces in terms of their in vitro biocompatibility, cytotoxicity, and metal release. The outcomes of the in vitro experiment show the successful culture of hMSCs on textured Ti6Al4V surfaces developed within this work. Cells cultured on LIPSS surfaces were not compromised in terms of their viability if compared to polished surfaces. Yet, the hMSC culture on UV-LIPSS show significantly lower lactate dehydrogenase and titanium release into the supernatant compared to polished. Thus, the presented surface modification can be a promising approach for future applications in orthodontics and orthopedics.     

Corrosion Resistance of 3D Printed Ti6Al4V Gyroid Lattices with Varying Porosity

Corrosion of medical implants is a possible failure mode via induced local inflammatory effects, systemic deposition and corrosion related mechanical failure. Cyclic potentiodynamic polarisation (CPP) testing was utilized to evaluate the effect of increased porosity (60% and 80%) and decreased wall thickness in gyroid lattice structures on the electrochemical behaviour of LPBF Ti6Al4V structures. The use of CPP allowed for the landmarks of breakdown potential, resting potential and vertex potential to be analysed, as well as facilitating the construction of Tafel plots and qualitative Goldberg analysis. The results indicated that 60% gyroid samples were most susceptible to the onset of pitting corrosion when compared to 80% gyroid and solid samples. This was shown through decreased breakdown and vertex potentials and were found to correlate to increased lattice surface area to void volume ratio. Tafel plots indicated that despite the earlier onset of pitting corrosion, both gyroid test groups displayed lower rates of corrosion per year, indicating a lower severity of corrosion. This study highlighted inherent tradeoffs between lattice optimisation and corrosion behaviour with a potential parabolic link between void volume, surface area and corrosion being identified. This potential link is supported by 60% gyroid samples having the lowest breakdown potentials, but investigation into other porosity ranges is suggested to support the hypothesis. All 3D printed materials studied here showed breakdown potentials higher than ASTM F2129′s suggestion of 800 mV for evaluation within the physiological environment, indicating that under static conditions pitting and crevice corrosion should not initiate within the body.     

Properties of Cold Sprayed Titanium and Titanium Alloy Coatings after Laser Surface Treatment

Additive manufacturing (AM) has seen remarkable development in recent years due to relatively high efficiency of the process. Cold spraying (CS) is a particular method of AM, in which titanium and titanium alloy powders are used. CS is a very competitive technology enabling the deposition of coatings, repairing machine parts, and manufacturing new components. For specific applications, the surface of cold-sprayed materials may require further processing. This paper reports an attempt to employ laser surface treatment (LST) of cold-sprayed coatings on an aluminium alloy substrate. The influence of laser beam interaction time on the coatings’ properties was analysed. The microstructure was investigated and observed employing scanning electron microscopy (SEM). To evaluate residual stress after CS and LST, the sin²ψ technique was used. Investigations were also performed on Vickers hardness, contact angle, and surface roughness. Significant changes in the surface morphology of the coatings and elevated residual stress levels dependent on the laser beam interaction time were observed. Increased Vickers hardness was recorded for titanium alloy Ti6Al4V. LST also led to increased surface hydrophilicity of the modified materials Ti and Ti6Al4V.     

Feedstock Development for Material Extrusion-Based Printing of Ti6Al4V Parts

In this work, a holistic approach for the fabrication of dense Ti6Al4V parts via material extrusion methods (MEX), such as fused filament fabrication (FFF) or fused feedstock deposition (FFD), will be presented. With respect to the requirements of the printing process, a comprehensive investigation of the feedstock development will be described. This covers mainly the amount ratio variation of the main binder components LDPE (low-density polyethylene), HDPE (high-density polyethylene), and wax, characterized by shear and oscillation rheology. Solid content of 60 vol% allowed the 3D printing of even more complex small parts in a reproducible manner. In some cases, the pellet-based FFD seems to be superior to the established FFF. After sintering, a density of 96.6% of theory could be achieved, an additional hot isostatic pressing delivered density values better than 99% of theory. The requirements (mechanical properties, carbon, and oxygen content) for the usage of medical implants (following ASTM F2885-17) were partially fulfilled or shortly missed.     

Corrosion of Stirred Electrochemical Nano-Crystalline Hydroxyapatite (HA) Coatings on Ti6Al4V

Ti6Al4V substrates were electrochemically deposited with nano-crystalline hydroxyapatite (HA) from aqueous electrolytes. Cathodic HA coatings were obtained when the electrolyte was stirred using ultrasonic vibration. Two current densities of 20 mA/cm² and 50 mA/cm² were employed. Polarization and electrochemical impedance spectroscopy (EIS) were the techniques used to estimate the corrosion of coatings in simulated body fluid (SBF). The results indicate good corrosion resistance for the coating obtained at 50 mA/cm² from ultrasonic stirring of the electrolyte.     

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity

Ti6Al4V alloy has been widely used in many fields, such as aerospace and medicine, due to its excellent biocompatibility and mechanical properties. Most high-performance components made of Ti6Al4V alloy usually need to be polished to produce their specific functional requirements. However, due to the material properties of Ti6Al4V, its polishing process still requires significant development. Therefore, this study aimed to investigate the performance of polishing Ti6Al4V by using tools with different rigidities. Two kinds of bonnet tool were used, namely a pure rubber (PR) bonnet and a semirigid (SR) bonnet. The characterization of material removal and surface integrity after polishing was conducted through a series of experiments on a 6-DOF robotic polishing device. The results demonstrate that both bonnet tools successfully produce nanometric level surface roughness. Moreover, the material removal rate of the SR bonnet tool is significantly higher than that of the PR bonnet, which is consistent with the material removal characteristics of glass polishing in previous research. In addition, the presented analysis on key polishing parameters and surface integrity lays the theoretical foundation for the polishing process of titanium alloy in different application fields.     

Water versus Oil Lubrication of Laser-Textured Ti6Al4V Alloy upon Addition of MoS2 Nanotubes for Green Tribology

A Nd-YAG laser was used for texturing the Ti6Al4V surface with dimples of diameter 50 and 100 µm and centre-to-centre distance 100, 200 and 400 µm, defining the surface texture density. The tribological evaluation was conducted to analyse and compare the behaviour of un-textured and laser-textured samples under water in comparison to oil (PAO6) lubrication without and with the addition of MoS₂ nanotubes into the lubricant. MoS₂ nanotubes had a positive effect on friction in both media for laser-textured Ti6Al4V. Evaluation of friction and wear in water and PAO6 showed a comparable tribological response in water to oil for specific laser-textured configurations, proving the novel concept of green tribology for laser texturing in combination with MoS₂ nanotubes/water lubrication.     

Tribological Characterization of the Heat-Assisted Single Point Incremental Forming Process Applied to the Ti6Al4V Alloy with the Definition of an Adhesion Parameter for the Tool Surface

Heat-assisted single point incremental forming or HA-SPIF has a great potential for producing one-piece batches of hard-to-form materials such as Ti6Al4V alloy for medical and aeronautical applications. One of the limitations of the process is the difficulty in achieving a reasonable surface finish, which makes essential the characterization of the tribological process in the tool–sheet contact. In fact, not much work can be found at this point in literature. In this research, a novel procedure for evaluating the adhesion on the tool surface is proposed and the influence of the temperature is determined. The surface finish of parts is analyzed, and the changes promoted by HA-SPIF appearing in the morphology of the external surface layer are characterized by SEM.