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FAST-forge of Diffusion Bonded Dissimilar Titanium Alloys: A Novel Hybrid Processing Approach for Next Generation Near-Net Shape Components

The University of Sheffield, Department of Material Science and Engineering, Sir Robert Hadfield Building, Sheffield S1 3JD, UK
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Metals 2019, 9(6), 654; https://doi.org/10.3390/met9060654
Received: 19 May 2019 / Revised: 1 June 2019 / Accepted: 3 June 2019 / Published: 4 June 2019
(This article belongs to the Special Issue Titanium Alloys: Processing and Properties)
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Abstract

Material reductions, weight savings, design optimisation, and a reduction in the environmental impact can be achieved by improving the performance of near-net shape (NNS) titanium alloy components. The method demonstrated in this paper is to use a solid-state approach, which includes diffusion bonding discrete layers of dissimilar titanium alloy powders (CP-Ti, Ti-6Al-4V and Ti-5Al-5Mo-5V-3Cr) using field-assisted sintering technology (FAST), followed by subsequent forging steps. This article demonstrates the hybrid process route, firstly through small-scale uni-axial compression tests and secondly through closed-die forging of dissimilar titanium alloy FAST preforms into an NNS (near-net shape) component. In order to characterise and simulate the underlying forging behaviour of dissimilar alloy combinations, uni-axial compression tests of FAST cylindrical samples provided flow stress behaviour and the effect of differing alloy volume fractions on the resistance to deformation and hot working behaviour. Despite the mismatch in the magnitude of flow stress between alloys, excellent structural bond integrity is maintained throughout. This is also reflected in the comparatively uncontrolled closed-die forging of the NNS demonstrator components. Microstructural analysis across the dissimilar diffusion bond line was undertaken in the components and finite element modelling software reliably predicts the strain distribution and bond line flow behaviour during the multi-step forging process. View Full-Text
Keywords: spark plasma sintering; thermomechanical processing; closed-die forging; process modelling; powder consolidation; downstream processing; titanium powder processing spark plasma sintering; thermomechanical processing; closed-die forging; process modelling; powder consolidation; downstream processing; titanium powder processing
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Pope, J.; Jackson, M. FAST-forge of Diffusion Bonded Dissimilar Titanium Alloys: A Novel Hybrid Processing Approach for Next Generation Near-Net Shape Components. Metals 2019, 9, 654.

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