Tungsten remains a material of considerable interest to engineers for nuclear fusion reactor designs, for the plasma-facing components (PFCs) thanks to its outstanding thermal conductivity and unmatched high melting point. However, tungsten remains a difficult to additively manufacture metal, due to its highly brittle nature, leading to cracking during cooling. In situ alloyed 90 wt

This study evaluates the effectiveness of these conventional heating methods, commonly adopted in the industry with long durations (typically one hour), in comparison to newer, potentially more efficient approaches such as induction coil heating, infrared module heating, and infrared furnaces that can perform solution heat treatment in significantly shorter times (5 to 20 min). The properties of the edge and centre regions of the solution-treated billets, including the state of precipitates, grain structures, and Vickers hardness, are investigated and compared. Results have shown that the 7075 billets heated by conventional heating methods sufficiently dissolved the stable precipitates, achieving hardness ranging from 137 to 141 HV, in contrast to the benchmark unheated, as-received sample of approximately 70 HV. In the meantime, the induction coil and infrared furnace demonstrate notable effectiveness, achieving hardness between 126 and 135 HV. The average grain sizes in the centre and edge regions for all samples are measured as 3 and 8 µm, respectively. However, the impact of the grain size on the hardness is negligible compared to the impact of the precipitates. Finite element (FE) modelling comparing the slowest heating method—the electric furnace—and the fastest heating method—induction coil heating—reveals the latter could heat the billet up to 450 °C at a rate ten times faster than the electric furnace. This study highlights the potential of novel heating techniques in promoting the efficiency of heat treatment processes for 7075 aluminium alloys.

Thermal modelling of additive manufacturing is a key method for furthering the quality of the components produced, as it allows for analysis that is not possible via experimental methods due to the difficulties involved with in situ monitoring. The thermal gradients present during the additive manufacturing process have a large impact on the formation of defects, such as porosity, residual stress, and cracking. The thermal gradients also have a large impact on material properties by controlling the microstructure formed. Thermal modelling methods are often based on numerical solutions of the heat conduction equation. Whilst numerical methods can be more accurate, they are often very slow because of the fine mesh requirements to capture high thermal gradients and iterative solvers to approximate the real-world solution to the required thermal field equations. An analytical model was developed to provide a fast solution to the problem. The analytical model used in this research was based on the Rosenthal equation and was analysed under a range of process parameters. A temperature-dependent Rosenthal model was also created with the aim of improving the results. The analytical model was then compared with a finite element numerical model to act as verification for the results. The analytical model accurately predicted the meltpool width over a range of process conditions. The analytical model underestimated the meltpool length compared to the numerical model, especially at high velocities. When using the standard Rosenthal model, the use of room-temperature or high-temperature thermal conductivities underestimated or overestimated the cooling rates from the meltpool, respectively. A temperature-dependent Rosenthal model was shown to produce more accurate cooling rates compared to the original Rosenthal equation.

Ti-6Al-4V warm forged fasteners are a critical part of the aerospace industry, as they are used in vast quantities for mechanical joining of components for the fuselage, wing-skin and aero-engine. These components are produced in vast quantities at rapid production rates through multi-blow axial forging However the rate that they are manufactured means that manufacturers rely upon periodic part conformance testing to understand if the part is within tolerance or if any undesirable manufacturing defects such as cracks or underfilling are present. Thus, a right-first-time manufacturing approach is essential to minimize non-conformant scrap. An analysis of the Ti-6Al-4V supplied raw material for axial forging, in a variety of different bar diameter sizes and from different industrial suppliers, was conducted. This was to attempt to understand whether material property variation or operator variation was the root cause for some material behaving differently during the manufacture route. Experimental testing was performed through microstructure characterization and mechanical testing methods. The volume fraction of the β-phase was noted to be marginally higher in material with good forgeability. The hardness of the inner core of the bar appears to be a critical material property for the Ti-6Al4V bar, with an overly hard bar-core hindering forgeability of the bar. This is believed to be due to the hotter central region malleability being key for forgeability. Micro-void porosity was also noted which could lead to stress concentration locations, or crack initiation, and as such is a deleterious property for forgeability. The experienced forgeability of the Ti-6Al-4V bars have been demonstrated to be sensitive to rather small variation in measured microstructure and mechanical property. It is believed that cumulative impacts of small differences, 1% variation in α-phase volume fraction, small variations in elongation to failure, 1% variation in elastic modulus and microhardness profile variation at the center of the bar of less than 10 HV0.3, can combine to significantly impact the forgeability of Ti-6Al-4V bar.

Interphase boundary plays a dominant role in the mechanical properties of dual-phase titanium alloys, and therefore mechanistic understandings of the effect of phase boundary on the plasticity is significant to tailor the microstructure for desired performance. In this study, compression tests were conducted on the Ti-6Al-4V micro-pillars with a dual-phase lamellar structure and designated crystallographic orientation of pillars and the number of interphase boundaries in the pillars were achieved by elaborate processing, to reveal the interphase boundary and its quantity on the dislocation behavior and critical resolved shear stress (CRSS) of the alloy. Transmission electron microscopy was employed to characterize the dislocations and their interplay with interphase boundaries during compression. It is found that in the pillars oriented for prismatic slip, which represents the hard mode for dislocation transmission through the α/β phase boundary, the strain distribution in the pillars was significantly delocalized by introducing interphase boundaries. More dislocation slip bands are generated owing to the strengthening effect from the interphase boundaries during compression, which results in a more homogeneous strain distribution. Moreover, quantitative analyses of the contribution of interphase boundaries on the CRSS were performed, and the interphase strength for prismatic slip was experimentally determined to be ∼ 50 MPa. The effect of pillar size on the CRSS value was also assessed. Although the CRSS of the pillars increases when their size decreases, the size dependency becomes much less pronounced when more interphase boundaries are introduced into the pillars. The underlying mechanisms for these phenomena were discussed based on the experimental results and finite element modeling. These results provide some new insights into the plasticity and strengthening mechanism of Ti-6Al-4V alloy, which are also applicable to other dual-phase titanium alloys.

The microstructural evolutions and variations in mechanical performance of electron beam welded (EBW) Ti-6Al-4V (Ti64) alloy have been investigated. The effects of heat treatment on the microstructure of welded samples have been studied after post-welding solution treatment and ageing. The martensitic phase α' has been confirmed using transmission electron microscopy (TEM). Electron backscatter diffraction (EBSD) has been used to investigate the phase and grain morphology. Results showed that the martensitic α′ phase coarsened, the size of heat-affected zone (HAZ) changed and grains in the base materials (BMs) had grown after the post-weld heat treatments (PWHT). The tensile behaviour of electron beam welded Ti64 has been investigated using in situ tensile testing monitored by optical microscopy. The deformation and failure were directly revealed during the in situ tensile process. Results showed that the EBW Ti64 samples have different failure locations after receiving different post-weld heat treatments. The relationship between the post-weld heat treatments, microstructural evolution and mechanical properties of EBW Ti64 were investigated. Thermodynamic databases were used to predict mechanical properties—including the yield strengths—of the titanium alloy for different grain sizes, representing different post-weld heat treatment operations, and these were embedded into a finite element modelling framework to simulate the tensile testing specimens to understand the mechanical fields experienced such as stresses and strains, just prior to failure.

Aerospace fasteners are a ubiquitous component within the aerospace, air-frame, and aero-engine industries due to the essential role they play in structural integrity. Ti-6Al-4V is a common material for fasteners to be manufactured from, owing to the excellent strength-to-density ratio the material possesses, allowing for weight-saving in an application where weight is penalised by loss of fuel efficiency. The manufacture of aerospace pins sees a solid-state lubricant applied over the surface of the bar stock, at the titanium manufacturers, which aids forging processing; however, this lubricant layer must be fully removed post-forging to allow for solution heat treatment operations to achieve the desired mechanical properties. Whilst the exact composition of the lubricant is proprietary to the titanium producers, this can make understanding the removal via salt bath processing difficult. As such, the lubricant has been analysed and characterised to understand the primary chemical composition of the lubricant. Furthermore, the salt bath process has been studied to understand the efficacy of the cleaning process and the impact that variation in the salt bath hold time has or that adding some method of agitation to the molten salt in the bath as it cleans the surface lubricant off the Ti-6Al-4V fastener has. The salt bath cleaning process can cause a bottleneck to the full manufacturing route for the aerospace fasteners. Results suggest that there is some margin to reduce the hold time, or that by adding in a dipping process to increase agitation, it can also allow for lower hold times.

The aluminium alloy AA2014 is one of the most widely used of the 2xxx series alloys, owing to its superior strength-to-weight ratio and stiffness. It is commonly forged to shape for use in aerospace parts. Three different small pilot-scale AA2014 billets were subjected to different heating operations, to physically simulate a pre-forge heating operation. The unheated sample and heated samples were then analysed for micro structural evolution and mechanical properties, to understand how the pre-forge heat treatments may vary the starting condition of the alloy before being forged. It was shown that an induction heating process has the greatest impact upon the precipitation distribution. Whilst this variation is commonly considered a negative impact, the opportunity to control the induction heating to promote preferential microstructure at specific locations within the billet may be possible.

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A detailed microstructural characterisation of the emerging weld-line grain structure, for bead-upon-plate welds in Ti-6Al-4V (Ti64) of differing plate thickness, was performed. The microstructure studied was formed during both steady state and non-steady state sections within the weld path, with the non-steady state portion being taken from the end of the plate as the weld bead and heat source overhang the edge of the plate. This allows for the effects of welding process conditions on the microstructural evolution to be determined. The weld pool geometry and 3D tomography of the weld-induced defects have been investigated. Detailed characterisation of microstructure and texture for different welding parameters and for steady and non-steady states have been used to identify physical parameters for the microstructure predictions that are difficult to obtain otherwise. The different states significantly affect the weld crown shape and formation, weld toe, weld bead depth and width. However, the heat affected zone (HAZ) remains unchanged. Regarding the microstructural evolution, both the steady and non-steady states have similar microstructure and texture. No defects were observed in the steady state section of welds, but sub-surface spherical pores have been observed in the non-steady state section of a weld. Finite element modelling to simulate the thermal-metallurgical-mechanical fields within the steady and non-steady state sections of the welds was considered, and the cooling rates predicted within steady state and non-steady sections were interrogated to improve the theoretical understanding of the microstructure and defect formation differences in these Ti64 EB weld regions.

Metal-processing operations, including casting, forging, forming, rolling, drawing, welding, machining and cutting, have provided the backbone to heavy industry and, as such, have been some of the principal drivers in the industrialization and manufacture of metal components for hundreds of years [...]

The velocity–versus-time rundown curves from two experimental Ti-6Al-4V inertia friction welds were analysed and differentiated several times, to produce rotational acceleration, jerk, jounce (or snap), crackle and pop versus-times curves for each weld. Titanium alloys and their mechanical properties are known to be highly sensitive to strain rate as the material is deformed, though nothing has ever been considered in terms of the higher-order time-derivatives of position. These curves have been studied and analysed further, for a more complete understanding of the derivative trends. Rotational acceleration and jerk traces both display behavior patterns across the two welds as the part rotates under action from the flywheel. The rotational snap also displays a pattern in this derivative during the final approximately 0.5 s of welding, as the energy dissipates. Evidence of a distinct oscillatory pattern in the rotational crackle and pop terms was noted for one weld when differentiating over a larger time-base, though could not be replicated in the 2nd weld. The higher derivative curves allow distinction of different process regimes, indicating that inertial energy mostly influences the time-base of dynamically steady-state phase. Qualitative differences between initial energies are evident in higher derivatives.

Manufacturing processes such as welding subject the α/β titanium alloy Ti-6Al-4V to a wide range of temperatures and temperature rates, generating microstructure variations in the phases and in the precipitate dimensions. In this study, the metallurgical and numerical modelling of Ti-6Al-4V when subjected to a high energy density welding process was affected by a series of analytical equations coded in Sysweld commercial specialist FE welding software. Numerical predictions were compared with experimental results from laser welding tests on plates with different thicknesses, initial microstructural morphologies, and operating conditions. The evolution of the microstructure was described by using a diffusion-based approach when the material was operating in the α + β field, whilst empirical equations were used for temperatures above the β-transus temperature. Predictions made by the subroutines within the FE model were shown to match with reasonable trends when validated using experimental characterisation methods for various metallurgical features, including the α particle size, β grain size, martensitic needle thickness, and relative phase volume fractions.

The thermodynamic heat-transfer mechanisms, which occur as a heated billet cools in an air environment, are of clear importance in determining the rate at which a heated billet cools. However, in finite element modelling simulations, the convective heat transfer term of the heat transfer mechanisms is often reduced to simplified or guessed constants, whereas thermal conductivity and radiative emissivity are entered as detailed temperature dependent functions. As such, in both natural and forced convection environments, the fundamental physical relationships for the Nusselt number, Reynolds number, Raleigh parameter, and Grashof parameter were consulted and combined to form a fundamental relationship for the natural convective heat transfer as a temperature-dependent function. This function was calculated using values for air as found in the literature. These functions were then applied within an FE framework for a simple billet cooling model, compared against FE predictions with constant convective coefficient, and further compared with experimental data for a real steel billet cooling. The modified, temperature-dependent convective transfer coefficient displayed an improved prediction of the cooling curves in the majority of experiments, although on occasion a constant value model also produced very similar predicted cooling curves. Finally, a grain growth kinetics numerical model was implemented in order to predict how different convective models influence grain size and, as such, mechanical properties. The resulting findings could offer improved cooling rate predictions for all types of FE models for metal forming and heat treatment operations.

A series of ring compression tests using BS970:708M40 alloy steel samples were studied. These tests were conducted using a 2-factor soak-temperature variable, namely 1030 °C and 1300 °C, and a 4-factor lubricant variable consisting of unlubricated samples, synthetic water-based, graphite water-based, and graphite and molybdenum disulphide viscous grease. The lubricant agents were all applied to the tool/billet interface. Process variables such as blow force and heating were controlled with the use of a gravitationally operated drop hammer and an automated programmable induction-heating unit. This matrix of the experimental parameters offered a sound base for exploring dominant factors impacting upon bulk deformation. This deformation was measured using fully calibrated equipment and then systematically recorded. A finite element modelling framework was developed to further improve the thermo-mechanical deformation process understanding, with finite element (FE) predictions validated through experimental measurement. Through the combined experimental and FE work, it was shown that temperature variation in the experimental parameter matrix played a larger role in determining deformation than the lubrication agent. Additionally, the use of synthetic and graphite water-based lubricants does not necessarily produce greater deformation when used in high-temperature forgings due to the lubricants breaking down, evaporating, or inducing rapid billet cooling as a result of the carrier used (water). Graphite-molybdenum disulphate grease far outperforms the other lubricants used in this trial in reducing friction and allowing deformation to occur across a die-face.

This paper demonstrates the application of a modified Avrami equation in the analysis of crystallisation curves obtained using differential scanning calorimetry (DSC). The model incorporates a square root of time dependence of the secondary process into the conventional Avrami equation and, although previously validated using laser flash analysis and infrared spectroscopy, is not currently transferable to DSC. Application of the model to calorimetric data required long-duration isotherms and a series of data treatments. Once implemented, the square root of time dependence of the secondary process was once again observed. After separation of the secondary process from the primary, a mechanistic n value of 3 was obtained for the primary process. Kinetic parameters obtained from the analysis were used in the model to regenerate the fractional crystallinity curves. Comparison of the model with experimental data generated R2 values in excess of 0.995. Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) was used as model polymer due to the prominent secondary crystallisation behaviour that this polymer is known to display.

A small series of ring compression tests were performed on BS970:708M40 alloy steel. The samples were tested using a 2-factor temperature variable, and a 4-factor lubricant variable, as the design parameters. Two differing soak temperatures were used, namely 1030 °C and 1300 °C respectively. The lubricants applied at the billet to tooling interface were synthetic water–based, graphite water–based, graphite and molybdenum disulphide viscous grease, and finally, unlubricated samples were tested. The ring compression tests were performed using a traditional drop forging hammer and induction heating to minimise any unintentional process variability. The impact that the two varying process parameters have upon the compression sample was then assessed by measuring each sample’s surface hardness and surface roughness prior to and post forging with fully calibrated equipment. It was demonstrated that the higher soak temperature of 1300 °C yielded a lower surface hardness value and higher surface roughness than the lower soak temperature, 1030 °C. The two water-based lubricants offered negligible change in results compared with the unlubricated forging, strongly suggesting that the lubricants were evaporated off the surface prior to forging. However, the results from the graphite–molybdenum disulphate grease do indicate in particular higher surface roughness than other lubricants, and a non-symmetric distortion pattern.

The microstructural kinetics of β grain growth in the β field of a Ti-6Al-4V alloy was studied by a series of controlled heat treatments at constant temperature rates. Heating rates of 5°C/s, 50°C/s and 500°C/s were considered, stopping at different peak temperatures. The thickness evolution of martensitic needles and lamellar α laths, formed on cooling, was also investigated, by soaking the material above its β-transus temperature and cooling down at 5°C/s, 50°C/s, 100°C/s and 300°C/s till ambient temperature. Quantitative microstructural analyses were used to measure the particle dimensions. The β grain growth kinetics was reasonably well described by a modified Avrami equation. The thickness of α lamellae was a function of the cooling rate and the β grain dimension in which they nucleated. The martensite needle thickness was shown to be a function of the cooling rate to which the material was subjected.

Constitutive modelling is of importance for metals and alloys which require hot working to improve their me-chanical strength. In the present work, a semi-empirical method has been proposed for alloy systems which experience strain hardening e.g. Cu-Cr based alloys, which is easy to implement. This method is based upon the Arrhenius equation, whereby a new parameter alpha representing the effective stress is introduced. This metho-dology allows for the effect of strain on the changing back stress to be taken into account, thus the method considers the coupled effects of strain, temperature and strain rate. The value of parameter alpha can be fitted using exponential function. Experimental data of flow curves during isothermal compression have been used to verify the present model. Compared to the conventional Arrhenius equation using polynomial fitting, the present model reduces the parameters to be fitted without sacrificing accuracy.

A microstructural characterisation and computational modelling framework for simulating the coupled thermal mechanical cycles with two different initial parent microstructures, and their impact upon the emerging microstructure features including beta grain size and phase volume fractions during electron beam welding (EBW) of Ti-6Al-4 V (Ti64) alloy is presented. Ti64 plates (measuring 5.5 mm in thickness) with different thermal processing have been electron beam welded using differing process parameter sets. These experimental welds have been fully characterised to provide information on the effect that a prior heat treatment has upon the micro structural evolution caused by the EB welding. Microstructure characterisation was investigated using both light microscopy and scanning electron microscopy. The results from this microstructure characterisation have been used to identity physically-based parameters required for microstructure predictions.