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<p>Ti-6Al-4V alloy is extensively used in the aerospace industry due to its high specific strength and excellent corrosion resistance. However, its limited workability makes the conventional manufacturing of aerospace fasteners complex, involving multiple steps such as cutting, rolling, drawing, heading, and heat treatment. In this study, an innovative warm-forging technique using a 1-die 2-blow system was developed to enable high-efficiency bulk production of fasteners with a uniform microstructure and enhanced strength. Finite element simulation was employed to optimize the forging temperature, ensuring effective material flow and minimal defects. Subsequently, the forged bolts were heat treated under optimized conditions to obtain a fine equiaxed α-phase. The heat treatment parameters including solution temperature (ºC), solution time (min), aging temperature (ºC), and aging time (h) were optimized using an artificial neural network (ANN) model to maximize strength (kN). The ANN predicted an optimal heat treatment condition of 927&#xa0;°C for 17&#xa0;min (solution treatment) followed by aging at 482&#xa0;°C for 4&#xa0;h. The α-phase size in the as-forged and optimally heat-treated Ti-6Al-4&#xa0;V bolts was 4 ± 1.2&#xa0;μm and 3.51 ± 0.97&#xa0;μm, respectively. The resulting aerospace-grade fasteners demonstrated a favorable combination of high strength and ductility, confirming the effectiveness of the proposed process.</p> Graphical Abstract <p></p>

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Optimized Process Design for Uniform Microstructure and High-Strength Ti-6Al-4 V Alloy Fasteners in Aerospace Applications

  • 期刊论文

  • 发表日期：

    2025年11月21日

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  • A. K. Maurya,
  • Jung-Woo Hwang,
  • Jong-Taek Yeom,
  • Jae Ho Kim,
  • Junha Yang,
  • Jae H. Kim,
  • JongSup Lim,
  • Sang Won Lee,
  • Chan Hee Park,
  • Jae Keun Hong,
  • N. S. Reddy

摘要

Ti-6Al-4V alloy is extensively used in the aerospace industry due to its high specific strength and excellent corrosion resistance. However, its limited workability makes the conventional manufacturing of aerospace fasteners complex, involving multiple steps such as cutting, rolling, drawing, heading, and heat treatment. In this study, an innovative warm-forging technique using a 1-die 2-blow system was developed to enable high-efficiency bulk production of fasteners with a uniform microstructure and enhanced strength. Finite element simulation was employed to optimize the forging temperature, ensuring effective material flow and minimal defects. Subsequently, the forged bolts were heat treated under optimized conditions to obtain a fine equiaxed α-phase. The heat treatment parameters including solution temperature (ºC), solution time (min), aging temperature (ºC), and aging time (h) were optimized using an artificial neural network (ANN) model to maximize strength (kN). The ANN predicted an optimal heat treatment condition of 927 °C for 17 min (solution treatment) followed by aging at 482 °C for 4 h. The α-phase size in the as-forged and optimally heat-treated Ti-6Al-4 V bolts was 4 ± 1.2 μm and 3.51 ± 0.97 μm, respectively. The resulting aerospace-grade fasteners demonstrated a favorable combination of high strength and ductility, confirming the effectiveness of the proposed process.

Graphical Abstract