Electrolyte jet machining for surface texturing of Inconel 718

Electrolyte jet machining is an emerging non-conventional machining process which is capable of selectively applying multi-scale surface textures. Surfaces processed in this way do not suffer from thermal damage and hence this technique is highly suited to finishing procedures in high value manufacturing across the aerospace and biomedical sectors. Furthermore, input variables can be modified dynamically to create functional graduation across component surfaces. In this study, the development and design of a custom-built EJM system is described, and the capability of the EJM platform to machine and create surface textures in Inconel 718, a widely used nickel based super alloy, is investigated. Through control of machine path programming and parameter variation, multi-scale surface textures are created which have the potential to enhance bonding with subsequent coating layers and also provide fluid dynamic advantage

Spheroidisation of metal powder by pulsed electron beam irradiation

A new powder spheroidisation process has been demonstrated using a large-area, pulsed electron beam technique. This was used to dramatically improve the surface morphology of Stellite 6 metal powder. Powder surface asperities up to 20 μm size can be eliminated by melting and incorporation into the near-surface of the particle. Surface finish is significantly improved. Agitation and rotation of particles due to a beam-induced stress wave enables the irradiation of multiples sides of particles, resulting in uniformly smoothed particles after sufficient pulses. Elemental analysis revealed no measurable contamination as a result of the process. Transmission electron microscopy showed a dense layer is produced within a zone up to 3 μm beneath the surface, with a substantially reduced grain size from ca. 2 μm diameter in the bulk to ca. 40 nm. Elemental homogenisation also was accompanied by grain refinement. The irradiated Stellite 6 showed a reduced basic flowability energy (583 mJ compared to 627 mJ for the untreated), explained by reduced particle-particle cohesion and interlocking, and an increased conditioned bulk density of 4.57 g/ml compared to 4.33 g/ml due to satellite/asperity reduction

Erosion resistance of laser clad Ti-6Al-4V/WC composite for waterjet tooling

AbstractIn waterjet operations, milled surfaces are left with some undesirable dimensional artefacts, thus the use of abrasion resistant mask has been proposed to improve the surface quality of machined components. In this study, the erosion performance of laser clad Ti-6Al-4V/WC composite coating subjected to plain water jet (PWJ) and abrasive water jet (AWJ) impacts to evaluate its potentials for use as waterjet impact resistant mask material and coating on components was investigated. Results showed that composite with 76wt.% WC composition subjected to PWJ and AWJ impacts offered resistance to erosion up to 13 and 8 times that of wrought Ti-6Al-4V respectively. Scanning electron microscopy (SEM) examination of the eroded composite surfaces showed that the erosion mechanism under PWJ impacts is based on the formation of erosion pits, tunnels and deep cavities especially in the interface between the WC particles and the composite matrix owing to lateral outflow jetting and hydraulic penetration. Composite suffered ploughing of the composite matrix, lateral cracking and chipping of embedded WC particles and WC pull-out under AWJ impacts. The composite performance is attributed to the embedded WC particles and the uniformly distributed nano-sized reaction products (TiC and W) reinforcing the ductile β-Ti composite matrix, with its mean hardness enhanced to 6.1GPa. The capability of the Ti-6Al-4V/WC composite coating was demonstrated by effective replication of a pattern on a composite mask to an aluminium plate subjected to selective milling by PWJ with an overall depth of 344μm. Thus, composite cladding for tooling purpose would make it possible to enhance the lifetime of jigs and fixtures and promote rapid machining using the water jet technique

Soluble abrasives for waterjet machining

© 2014 Taylor & Francis Group, LLC. The addition of hard abrasives to the jet in waterjet machining can improve machining rate, however, embedding of particles in machined surfaces is a limitation, which results in reduced fatigue life, and limits the application of well adhered subsequent coatings to the surface. In this study, softer soluble abrasives were investigated as a potential solution. Soluble abrasives yielded a higher material removal rate compared to plain waterjet, although were not as effective as traditional hard abrasives. Soluble abrasives reduced grit embedment on all four workpiece materials. A post-machining surface cleaning operation demonstrated that any remaining soluble abrasive could be removed

Development of metal matrix composites by direct energy deposition of ‘satellited’ powders

Limited research has been undertaken investigating the material design freedoms that are granted through the use of additive manufacturing methods, especially in the development of materials specifically formulated for additive processes. In this study, a new material combination was evaluated for use with directed energy deposition methods of additive manufacturing. Here, a Ti-6Al-4 V powder is processed in combination with a much finer titanium diboride powder following a satelliting procedure. The resulting combination consists of large Ti-6Al-4 V particles encased in finer titanium diboride. Deposited composites presented exhibit TiB needles associated with increased hardness. Processing conditions were detailed which permit the deposition of the prepared feedstock onto Ti-6Al-4 V substrates. Microstructural characterisation revealed that the composite was made up of eutectic TiB precipitates dispersed in α-β Ti matrix with few partially melted Ti-6Al-4 V and TiB2 particles. Satelliting TiB2 powder onto Ti-6Al-4 V particle surfaces has significantly improved the homogeneity of composite which is characterised with randomly oriented and uniform distribution of TiB needles in the microstructure. Hardness of composites ranged between 440–480 HV. Hence, the feedstock preparation method proposed has been found to be effective and can be adapted for low cost and rapid formulation of a host of materials for processing by additive manufacture

Physical and electrical characteristics of EDM debris

AbstractIn EDM, debris plays a key role in the electrical conditions of the discharge gap prior to each spark. Despite this, analysis of debris at all length-scales has not yet been performed, and therefore the nature of debris produced by electrical discharge processes is not fully understood. In this study debris created by the machining of two electrode materials set as negative polarity, silicon and titanium carbide, was centrifuged and imaged using SEM and TEM. From this analysis it was shown that electrode debris is 1nm or lower and up to 10μm in size. Population analysis of the particle size distribution was used to inform an electric field model based on a lattice Boltzmann method framework, simulating the effect of the presence of such debris on the electric field strength. This method is shown to be able to capture the local variation of the electric field and predict qualitatively the correct trend of the electric field strength increasing against the debris concentration. Such data is important for prediction and control of discharge gap size, as well as understanding the impact of a build-up of debris on uncontrolled sparking

The creep behaviour of nickel alloy 718 manufactured by laser powder bed fusion

Components manufactured by laser powder bed fusion (LPBF) are limited by their performance for use in critical applications. LPBF materials have microstructural defects, such as suboptimal grain size and morphology, and macroscale anomalies, such as lack of fusion. This results in LPBF components performing below their wrought counterparts for various mechanical properties, such as creep which has seldom been researched. To understand the creep behaviour of LPBF alloy 718, parts were fabricated using different scanning strategies and build orientations and creep tested at 650 °C under a 600 MPa load. Heat treatment increased the creep life by a factor of 5, confirming its necessity. The build orientation and stress state were shown to be determining factors in the creep failure mechanisms. The Meander scanning strategy resulted in a 58% increase in creep life compared to the Stripe strategy, due to the detrimental effects of the numerous laser overlapping regions in the Stripe strategy. For a given strategy, a 24% increase in creep life compared to wrought alloy 718 was observed, indicating that LPBF has the potential to surpass wrought material properties. As a result of this work, it is possible to propose build strategies for high temperature creep applications

Effect of prior laser microstructural refinement on the formation of amorphous layer in an Al86Co7.6Ce6.4 alloy

Laser surface melting (LSM) pre-treatment was conducted before large area electron beam (LAEB) treatment in an attempt to eliminate the cracking of the amorphous layer. In our previous work, LAEB treatment successfully generated an amorphous layer on a cast polycrystalline Al-Co-Ce glass forming alloy. However, cracking was found and was associated with large and brittle Al8Co2Ce phase in the bulk material. Results show that prior LSM treatment in this present work can effectively refine the microstructure of as-cast material, decreasing the particle size and particle spacing of Al8Co2Ce phase. This decrease in the microstructural length scale greatly reduced the results of cracking of the amorphous layer. The LAEB pulse number required for the homogenisation and amorphisation of treated layer was also decreased for the laser pre-treated sample compared to as-cast material