Browsing by Author "Davis, A. E."

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    Achieving a columnar-to-equiaxed transition through dendrite twinning in high deposition rate additively manufactured titanium alloys
    (Springer, 2024-04-09) Davis, A. E.; Wainwright, J.; Sahu, V. K.; Dreelan, D.; Chen, Xin; Ding, Jialuo; Flint, T.; Williams, Stewart; Prangnell, Philip B.
    The coarse β-grain structures typically found in titanium alloys like Ti–6Al–4V (wt pct, Ti64) and Ti–6Al–2Sn–4Zr–2Mo–0.1Si (Ti6242), produced by high deposition rate additive manufacturing (AM) processes, are detrimental to mechanical performance. Certain modified processing conditions have been shown to lead to a more refined grain structure, which has generally been attributed to a change in the solidification conditions with respect to the experimental Hunt diagram proposed by Semiatin and Kobryn. It is shown that with Wire Arc AM (WAAM) increasing the wire feed speed (WFS) is effective in promoting a columnar-equiaxed transition (CET). Conversely, estimates of the dendrite-tip undercooling using the KGT model suggest that this will be too small for free nucleation without the addition of artificial nucleants, due to the very low solute partitioning in Ti alloys. It is also shown that it is difficult to promote a CET with plasma transferred arc WAAM as computational fluid dynamics (CFD) melt-pool simulations indicate that the solidification parameters remain within the columnar region on the Semiatin-Kobryn Hunt map, within the constraints of a stable process. However, a high fraction of twin boundaries was observed in the refined β-grain structures seen at high WFS. This has been attributed to departure of {001}β alignment from the direction of maximum thermal gradient, caused by the curvature of the fusion boundary, stimulating dendrite twinning during solidification. In addition, it is shown that increasing the WFS leads to a change in melt-pool geometry and a reduction of remelt depth, which promoted dendrite twinning and grain refinement.
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    On the chemical composition, microstructure and mechanical properties of a Nitrogen-contaminated Ti-6Al-4V component built by Wire-Arc Additive Manufacturing
    (IOP Publishing, 2024-08-01) Hu, Dongchen; Biswal, R.; Sahu, V. K.; Fellowes, J. W.; Zadehkabir, A.; Williams, Stewart W.; Davis, A. E.
    Additive manufacturing (AM) using recycled Ti-6Al-4V (Ti64) feedstock material from wrought waste streams is a novel process that can reduce the overall energy cost and carbon (CO2) footprint when compared to primary-production routes. The potential contamination of recycled feedstock material (e.g. C, O, N and Fe) can affect the microstructure and mechanical properties of the component. In this work, a Ti64 test wall built using wire arc AM (WAAM) was studied, where the top half only was contaminated by N through the shielding gas during deposition. This allowed a direct comparison of Ti64 WAAM material with high and low N content, deposited under otherwise identical conditions, to replicate the worst-case scenario of N contamination from using recycled swarf. The hardness of the N-contaminated section was found to be 25% higher than the uncontaminated section of the wall, demonstrating the N solid solution strengthening in Ti64. The room temperature transformed microstructure was found to have a 25% coarser α-lath thickness, which was proposed to be an effect of the AM cyclical heating and increasing of the β-transus temperature due to a higher level of N. Additionally, the outer layer of the N-contaminated sample section was found to have a refined parent β grain structure.