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<p>High specific strength, excellent corrosion resistance and good fracture toughness together make Titanium Alloy Ti6Al4V suitable for high pressure gas bottles in aerospace applications. Additive Manufacturing (AM) is a cost-effective and faster alternate fabrication route for hemispherical domes required for gas bottles. Co-axial Electron beam Wire-fed Additive Manufacturing (CEWAM) process was used to realize a hemispherical dome of Ø400&#xa0;mm using Ti6Al4V wire. Double track deposition strategy with precise regulation of printing parameters was employed to 3D print the dome. Suitability of the CEWAM process for aerospace application was studied by carrying out product level testing and evaluation. Heat treatment studies were performed to achieve uniformity in mechanical properties by tailoring the microstructure. Duplex annealing (DA) resulted in the optimum combination of strength and ductility. Minimal anisotropy in tensile strength and fracture toughness across the different locations and orientations of the dome was confirmed by extensive testing from bottom, middle and top locations of the dome. Grain orientation maps exhibited <i>α</i> lamellae along various crystallographic orientations in transformed <i>β</i> matrix. Optimized CEWAM process followed by duplex annealing heat treatment resulted in the formation of a uniform microstructure with a bimodal <i>α</i> + <i>β</i> lamellar structure throughout the product making it suitable for the stringent aerospace application.</p>

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Tailoring the Mechanical Properties of Ti6Al4V Dome 3D Printed by Co-axial Wire-Fed Electron Beam Directed Energy Deposition Processs

  • 期刊论文

  • 发表日期：

    2025年4月23日

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  • P. I. Pradeep,
  • V. Anil Kumar,
  • P. Senthil,
  • Dmytro Kovalchuk,
  • Apurba Roy

摘要

High specific strength, excellent corrosion resistance and good fracture toughness together make Titanium Alloy Ti6Al4V suitable for high pressure gas bottles in aerospace applications. Additive Manufacturing (AM) is a cost-effective and faster alternate fabrication route for hemispherical domes required for gas bottles. Co-axial Electron beam Wire-fed Additive Manufacturing (CEWAM) process was used to realize a hemispherical dome of Ø400 mm using Ti6Al4V wire. Double track deposition strategy with precise regulation of printing parameters was employed to 3D print the dome. Suitability of the CEWAM process for aerospace application was studied by carrying out product level testing and evaluation. Heat treatment studies were performed to achieve uniformity in mechanical properties by tailoring the microstructure. Duplex annealing (DA) resulted in the optimum combination of strength and ductility. Minimal anisotropy in tensile strength and fracture toughness across the different locations and orientations of the dome was confirmed by extensive testing from bottom, middle and top locations of the dome. Grain orientation maps exhibited α lamellae along various crystallographic orientations in transformed β matrix. Optimized CEWAM process followed by duplex annealing heat treatment resulted in the formation of a uniform microstructure with a bimodal α + β lamellar structure throughout the product making it suitable for the stringent aerospace application.