On the Choice of Tool Material in Friction Stir Welding of Titanium Alloys

Friction Stir Welding (FSW) is a solid state welding process patented in 1991 by TWI; initially adopted to weld aluminum alloys, is now being successfully used also for magnesium alloys, copper and steels. The wide diffusion the process is having is due to the possibility to weld both materials traditionally considered difficult to be welded or "unweldable" by traditional fusion welding processes due to peculiar thermal and chemical material properties, and complex geometries as sandwich structures and straightening panels. Recently, research is focusing on titanium alloys thanks to the high interest that such materials are getting from the industry due to the extremely high strength-weight ratio together with good corrosion resistance properties. At the moment, the main limit to the industrial applicability of FSW to titanium alloys is the tool life, as ultra wear and deformation resistant materials must be used. In this paper a, experimental study of the tool life in FSW of titanium alloys sheets at the varying of the main process parameters is performed. Numerical simulation provided important information for the fixture design and analysis of results. Tungsten and Rhenium alloy W25Re tools are found to be the most reliable among the ones considered

Material Flow in FSW of T-joints: Experimental and Numerical Analysis

In the paper the authors present the results of both an experimental and a numerical campaign focused on the analysis of the occurring material flow in the FSW of T joints of aluminum alloys. In particular to investigate the metal flow experimental tests and observations has been developed utilizing a thin foil of copper as marker placed between the skin and the stringer. In this way, the actual metal flow occurring during the FSW of T-joints has been highlighted together with the real bonding surface. The acquired information is definitively useful in order to choose effective set of process parameters, improving the process mechanics and avoiding the insurgence of defects

Progresses in multi-materials billet manufacturing out of metal scraps through friction stir consolidation

The evolution of Friction Stir Consolidation (FSC) from recycling towards upcycling technique proved to be one of the excellent solid-state methods for manufacturing functionally graded billets. Multi-material Functional Graded Materials (FGMs) represent a novel class of materials characterized by a gradual change in properties and functions which can be tailored to enhance components performance. Manufacturing techniques play a critical role in achieving the designed compositional and microstructural distribution. Specifically, FSC allows the manufacturing of FGM billets out of metallic chips; the mixing of different metallic chips offers mutually exclusive mechanical properties like high hardness and good ductility in a single FSC billet with excellent formability. The present research further explores some challenges while combining dissimilar aluminum alloys chips in different percentages and spatial order, especially in the radial direction. The mechanical and metallurgical properties were assessed through the Vickers hardness measurements and microstructure analysis. The results revealed that new strategies are needed for a better exploitation of FSC as a solid-state method for fabrication of Functionally Graded Materia

On the Choice of Tool Material in Friction Stir Welding of Titanium Alloys

Friction Stir Welding (FSW) is a solid state welding process patented in 1991 by TWI; initially adopted to weld aluminum alloys, is now being successfully used also for magnesium alloys, copper and steels. The wide diffusion the process is having is due to the possibility to weld both materials traditionally considered difficult to be welded or “unweldable” by traditional fusion welding processes due to peculiar thermal and chemical material properties, and complex geometries as sandwich structures and straightening panels. Recently, research is focusing on titanium alloys thanks to the high interest that such materials are getting from the industry due to the extremely high strength-weight ratio together with good corrosion resistance properties. At the moment, the main limit to the industrial applicability of FSW to titanium alloys is the tool life, as ultra wear and deformation resistant materials must be used. In this paper a, experimental study of the tool life in FSW of titanium alloys sheets at the varying of the main process parameters is performed. Numerical simulation provided important information for the fixture design and analysis of results. Tungsten and Rhenium alloy W25Re tools are found to be the most reliable among the ones considered

Mappe di Lavorabilita\u2019 per Giunti Misti di Alluminio Mediante Processo di Saldatura Linear Friction Welding

Il Linear Friction Welding \ue8 un processo di saldatura allo stato solido in cui una parte fissa \ue8 forzata contro una parte che si muove con moto lineare alternato per generare calore attraverso l\u2019attrito. Nel presente lavoro viene descritto lo studio effettuato per la realizzazione della giunzione mista mediante processo di Linear Friction Welding tra due leghe di alluminio che presentano propriet\ue0 meccaniche differenti, come la lega AA2011 e AA6082. Lo studio \ue8 stato condotto analizzando due differenti configurazioni determinate dalla posizione relativa delle leghe costituenti i provini da saldare. Per la realizzazione del processo \ue8 stata utilizzata una macchina prototipale dotata di sensori atti alla misura \u201cin process\u201d di variabili fondamentali per la completa comprensione del processo quali temperature nei provini, forze sui provini, accelerazioni e velocit\ue0 che questi subiscono

An Experimental Investigation of Residual Stresses in Hard Machining of AISI 52100 Steel

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In-stent restenosis of superficial femoral artery: use all arrows in the quiver.

In-stent restenosis (ISR) is a common superficial femoral artery (SFA) stenting complication, occurring in more than one third of patients within 2-3 years after the index procedure. Moreover, there is no standard treatment for ISR, and although many options are available, there is still limited data regarding its optimal management. We report a paradigmatic case report of a patient complaining of symptomatic peripheral arterial disease, underwent multiple endovascular revascularizations for recurrent femoro-popliteal ISR. A step-by-step approach was followed. At the time of the first presentation, the ISR was treated by drug-eluting balloon (DEB) angioplasty. The repeated ISR was treated by laser debulking, achieving a good angiographic result. Finally, after the third repeated restenosis, a combined approach with laser debulking and DEB angioplasty guaranteed a good acute angiographic result. Long-term duplex-scan follow-up demonstrated the good patency of the femoro-popliteal target lesion

Right anterior mini-thoracotomy vs. conventional sternotomy for aortic valve replacement: A propensity-matched comparison

Background: Right anterior mini-thoracotomy (MIAVR) is a promising technique for aortic valve replacement. We aimed at comparing its outcomes with those obtained in a propensity-matched group of patients undergoing sternotomy at our two high-volume centers. Methods: Main clinical and operative data of patients undergoing aortic valve replacement between January 2010 and May 2016 were retrospectively collected. A total of 678 patients were treated with a standard full sternotomy approach, while MIAVR was performed in 502. Propensity score matching identified 363 patients per each group. Results: In-hospital mortality was not significantly different between the propensity-matched groups (1.7% in MIAVR patients vs. 2.2% in conventional sternotomy patients; P=0.79). No significant difference in the incidence of major post-operative complications was observed. Post-operative ventilation times (median 7, range 5-12 hours in MIAVR patients vs. median 7, range 5-12 in conventional sternotomy patients; P=0.72) were not significantly different between the two groups. Cardiopulmonary bypass time (61.0±21.0 vs. 65.9±24.7 min in conventional sternotomy group; P < 0.01) and aortic cross-clamping time (48.3±16.7 vs. 53.2±19.6 min in full sternotomy group; P < 0.01) were shorter in MIAVR group. EuroSCORE (OR 1.52, 95% CI, 1.12-2.06; P < 0.01) was found to be the only independent predictor of intra-hospital mortality in the whole propensity-matched population. Conclusions: Our experience shows that mini-access isolated aortic valve surgery is a reproducible, safe and effective procedure with similar outcomes and no longer operative times compared to conventional sternotomy

Characterization of shape and dimensional accuracy of incrementally formed titanium sheet parts with intermediate curvatures between two feature types

Single point incremental forming (SPIF) is a relatively new manufacturing process that has been recently used to form medical grade titanium sheets for implant devices. However, one limitation of the SPIF process may be characterized by dimensional inaccuracies of the final part as compared with the original designed part model. Elimination of these inaccuracies is critical to forming medical implants to meet required tolerances. Prior work on accuracy characterization has shown that feature behavior is important in predicting accuracy. In this study, a set of basic geometric shapes consisting of ruled and freeform features were formed using SPIF to characterize the dimensional inaccuracies of grade 1 titanium sheet parts. Response surface functions using multivariate adaptive regression splines (MARS) are then generated to model the deviations at individual vertices of the STL model of the part as a function of geometric shape parameters such as curvature, depth, distance to feature borders, wall angle, etc. The generated response functions are further used to predict dimensional deviations in a specific clinical implant case where the curvatures in the part lie between that of ruled features and freeform features. It is shown that a mixed-MARS response surface model using a weighted average of the ruled and freeform surface models can be used for such a case to improve the mean prediction accuracy within ±0.5 mm. The predicted deviations show a reasonable match with the actual formed shape for the implant case and are used to generate optimized tool paths for minimized shape and dimensional inaccuracy. Further, an implant part is then made using the accuracy characterization functions for improved accuracy. The results show an improvement in shape and dimensional accuracy of incrementally formed titanium medical implants

Titanium based cranial reconstruction using incremental sheet forming

In this paper, we report recent work in cranial plate manufacturing using incremental sheet forming (ISF) process. With a typical cranial shape, the ISF process was used to manufacture the titanium cranial shape by using different ISF tooling solutions with and without backing plates. Detailed evaluation of the ISF process including material deformation and thinning, geometric accuracy and surface finish was conducted by using a combination of experimental testing and Finite Element (FE) simulation. The results show that satisfactory cranial shape can be achieved with sufficient accuracy and surface finish by using a feature based tool path generation method and new ISF tooling design. The results also demonstrate that the ISF based cranial reconstruction has the potential to achieve considerable lead time reduction as compared to conventional methods for cranial plate manufacturing. This outcome indicates that there is a potential for the ISF process to achieve technological advances and economic benefits as well as improvement to quality of life