Scholarlink

<p>Ti–6Al–4V additive manufacturing faces critical and persistent fabrication challenges like oxygen-induced embrittlement, dimensional inaccuracy, unsustainable material waste and high production costs. This study presents the novel approach in Ti–6Al–4V through the development of an indigenously engineered, hermetically sealed Wire Arc Additive Manufacturing (WAAM) system powered by Gas Tungsten Arc Welding. This system achieves ultra-clean atmospheric conditions (O₂ &lt; 10&#xa0;ppm), enabling defect-free deposition and near-theoretical density (99.98%) without a vacuum setup. The WAAM platform is also modified to ensure precision linear motion system (± 0.1&#xa0;mm) with synchronized Z-axis control to ensure geometric fidelity, and dimensional stability. In terms of sustainability, the process demonstrated 85% material savings, 50% specific energy consumption than CNC machining, and a carbon footprint of 85.90&#xa0;kg CO₂/kg, underlining its environmental and economic advantages. The deposition exhibited a refined Widmanstatten microstructure, contributing to improved performance including ultimate tensile strength of 964.43 ± 28.79&#xa0;MPa, flexural modulus of 266 GPa, average microhardness of 348 HV, and a dry sliding wear rate of 2.4 × 10⁻<sup>5</sup> mm<sup>3</sup>/Nm, which is approximately 40% lower than conventionally manufactured counterparts. These findings establish hermetically sealed WAAM as a scalable, oxidation-free, and sustainable route for fabricating high-performance Ti–6Al–4V components, offering transformative potential for aerospace and marine applications.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Investigating the effect of hermetic sealing on oxidation suppression and property enhancement in WAAM-processed Ti–6Al–4V

  • 期刊论文

  • 发表日期：

    2025年9月23日

查看全文
  • Sai Kiran Kaleru,
  • Ravi Shanker Vidyarthy,
  • Suresh Kumar Reddy Narala

摘要

Ti–6Al–4V additive manufacturing faces critical and persistent fabrication challenges like oxygen-induced embrittlement, dimensional inaccuracy, unsustainable material waste and high production costs. This study presents the novel approach in Ti–6Al–4V through the development of an indigenously engineered, hermetically sealed Wire Arc Additive Manufacturing (WAAM) system powered by Gas Tungsten Arc Welding. This system achieves ultra-clean atmospheric conditions (O₂ < 10 ppm), enabling defect-free deposition and near-theoretical density (99.98%) without a vacuum setup. The WAAM platform is also modified to ensure precision linear motion system (± 0.1 mm) with synchronized Z-axis control to ensure geometric fidelity, and dimensional stability. In terms of sustainability, the process demonstrated 85% material savings, 50% specific energy consumption than CNC machining, and a carbon footprint of 85.90 kg CO₂/kg, underlining its environmental and economic advantages. The deposition exhibited a refined Widmanstatten microstructure, contributing to improved performance including ultimate tensile strength of 964.43 ± 28.79 MPa, flexural modulus of 266 GPa, average microhardness of 348 HV, and a dry sliding wear rate of 2.4 × 10⁻5 mm3/Nm, which is approximately 40% lower than conventionally manufactured counterparts. These findings establish hermetically sealed WAAM as a scalable, oxidation-free, and sustainable route for fabricating high-performance Ti–6Al–4V components, offering transformative potential for aerospace and marine applications.