Search Results (79)

This article presents a review of current trends in the development of protective coatings for TiAl alloys. These materials have been indicated as potential replacements for nickel-based alloys for several decades; however, many problems related to their application have not yet been solved, such as low resistance to oxidation and high-temperature corrosion, limited wear and erosion resistance, as well as susceptibility to microstructural changes under demanding conditions. Research in this area has been conducted for many years; nevertheless, new concepts and types of coatings are constantly being developed, particularly for third- and fourth-generation TiAl alloys. This article presents a review and classification of protective coatings used for TiAl alloys, with particular emphasis on research results published in the scientific literature of the last decade. In addition to a literature review concerning coating types and applied technologies, new trends and concepts in this field proposed by the co-authors will also be presented. Full article

Laser processing has been widely investigated as an effective approach for improving surface properties and consolidating advanced materials, particularly complex alloys such as titanium aluminides (TiAl). In this study, laser surface remelting was applied to binary (Ti-45Al) and ternary (Ti-45Al-2Co and Ti-45Al-2Ni) alloys produced by powder metallurgy via blended elemental (BE) and pre-alloyed (PA) powder routes. Laser powers of 50 and 100 W were employed, resulting in a high-energy-density surface remelting regime applied to both green compacts and sintered samples with relatively high initial porosity, under an argon-controlled atmosphere. Microstructural and phase analyses were performed using scanning electron microscopy (SEM) and X-ray diffraction (XRD), while mechanical behavior was assessed by instrumented microindentation. Laser processing promoted the formation of a dense and homogeneous surface layer, approximately 150 μm thick, accompanied by significant microstructural refinement and enhanced hardness and elastic modulus. While rapid solidification led to crack formation in laser-treated sintered samples, the green compacts exhibited defect-free modified layers. Overall, the results demonstrate that laser surface remelting is an effective strategy for enhancing the surface integrity and mechanical performance of TiAl alloys processed by powder metallurgy. Full article

Despite their potential to improve properties such as the high-temperature strength required for jet engine blades, low-Al TiAl alloys have largely been overlooked. The most significant challenge is ensuring impact resistance, which is crucial for jet engine blade applications. First, this study evaluated the impact resistance of fully lamellar Ti-38.75–50.25 Al binary alloys in relation to the effects of α₂ phase ratio and spacing using a Charpy impact test. Subsequently, the impact of reducing Al content in Cr-added forged alloys and cast TiAl4822 was investigated. The results revealed that α₂ phase spacing had the most significant impact on impact resistance at 800 °C. Coarse α₂ phase spacing of approximately 6 μm, created in the high-Al material, provided the highest impact resistance. In contrast, the impact resistance of the low-Al material was low due to its extremely narrow α₂ phase spacing. In forged alloys, reducing both Al content and β-stabilizing elements enabled the removal of the deleterious β phase through heat treatment, while maintaining good forgeability, thereby improving impact resistance and creep strength. In low-Al TiAl4822, the expected improvement in creep strength could not be achieved because the low-strength γ phase located at lamellar colony boundaries underwent preferential deformation. Full article

Titanium aluminide intermetallics have gained considerable attention as high-temperature structural materials for aerospace applications, but are susceptible to “titanium fire” under extreme service conditions. The role of Al elements on the combustion behavior of titanium aluminide intermetallics remains not fully understood. Herein, the influence of Al content on the ignition critical condition and burning rate of Ti_1−xAl_x alloys was investigated by using promoted ignition combustion (PIC) tests under oxygen-enriched atmosphere. Results indicated that the critical oxygen pressure of Ti_1−xAl_x alloys increases from 0.11 MPa to 0.23 MPa, and the ignition temperature under oxygen pressure of 0.41 MPa increases from 1059.5 ± 4.8 K to 1120.4 ± 2.5 K as Al content increases from 20 at% to 70 at%. However, the combustion rate increases from 11.85 ± 0.13 mm·s⁻¹ to 14.05 ± 0.09 mm·s⁻¹ as Al content increases from 20 at% to 70 at%. Moreover, the activation energy for ignition increases from 105.44 kJ·mol⁻¹ to 153.04 kJ·mol⁻¹ as Al content increases from 20 at% to 70 at%. According to the microstructure analysis after combustion, the influence of Al content on the ignition activation energy and burning rate is attributed to multiple factors involving bonding energy, melting temperature, and heat release. Full article

Aluminum anodizing has been a well-established method of corrosion protection for over a century. A nanoporous and hexagonally arranged anodic aluminum oxide has become one of the most important template materials in nanotechnology. A totally new branch of research in anodizing was sparked by purple gold anodizing. This pioneering research showed that metal aluminides can be anodized and result in new classes of nanomaterials. Simultaneously, materials from Ti-Al systems were anodized, and the transition from nanopores to the nanotubes was mechanistically understood. Also, materials like Ni₃Al were anodized; however, the most frequently used aluminides are materials from the Fe-Al binary phase diagram, from Fe₃Al to FeAl₃. The research on metal aluminides has shown that it is possible to obtain mixed oxides with a highly developed nanostructured morphology. A significant amount of fundamental research has shown it is possible to obtain such mixed oxides with tunable band gaps, depending on the substrate material, anodizing conditions, and heat treatment. Despite significant progress in fundamental research, there is a noticeable lack of applied research on this class of materials. Full article

This study explores a novel approach to enhance the surface properties of Ti-Al alloys for biomedical applications by creating a compositional gradient layer through aluminum deposition using Electrical Discharge Machining (EDM). The primary goal was to develop a metallurgically bonded intermetallic zone that supports strong adhesion and improved compatibility for subsequent hydroxyapatite (HA) deposition. Aluminum was deposited onto a Ti6Al4V substrate via EDM under controlled conditions, followed by thermal and thermochemical treatments to induce diffusion and intermetallic phase formation. Comprehensive analyses using optical and electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD) revealed the formation of well-adhered layers composed of complex Ti-Al intermetallics such as TiAl₂ and TiAl₃, along with oxide phases including TiO₂ and Al₂O₃. Thermal and thermochemical treatments further improved surface hardness, reaching up to 1057 HV, and influenced the diffusion behavior of aluminum, titanium, and vanadium. Adhesion tests confirmed that the untreated and thermochemically treated layers exhibited superior mechanical stability, while thermal treatment alone led to brittleness and delamination. These findings demonstrate that a properly engineered intermediate aluminide layer can significantly improve the performance of bioceramic coatings, particularly HA, by providing enhanced structural integrity and biocompatibility. Full article

This study investigates TNM-type titanium aluminide alloys, representing the third generation of β-stabilized γ-TiAl heat-resistant materials. The aim of this work is to study the combustion characteristics and to produce compact materials via the free SHS compaction method from initial powder reagents taken in the following ratio (wt%): 51.85Ti–43Al–4Nb–1Mo–0.15B, as well as to determine the effect of high-temperature isothermal annealing at 1000 °C on the structure and properties of the obtained materials. Using free SHS compression (self-propagating high-temperature synthesis), we synthesized compact materials from a 51.85Ti–43Al–4Nb–1Mo–0.15B (wt%) powder blend. Key combustion parameters were optimized to maximize the synthesis temperature, employing a chemical ignition system. The as-fabricated materials exhibit a layered macrostructure with wavy interfaces, aligned parallel to material flow during compression. Post-synthesis isothermal annealing at 1000 °C for 3 h promoted further phase transformations, enhancing mechanical properties including microhardness (up to 7.4 GPa), Young’s modulus (up to 200 GPa) and elastic recovery (up to 31.8%). X-ray powder diffraction, SEM, and EDS analyses confirmed solid-state diffusion as the primary mechanism for element interaction during synthesis and annealing. The developed materials show promise as PVD targets for depositing heat-resistant coatings. Full article

Ultrasonic-assisted machining (UAM) has emerged as a transformative technology for increasing material removal efficiency, improving surface quality and extending tool life in precision manufacturing. This review specifically focuses on the application of it to titanium aluminide (TiAl) alloys. These alloys are widely used in aerospace and automotive sectors due to their low density, high strength and poor machinability. This review covers various aspects of UAM, including ultrasonic vibration-assisted turning (UVAT), milling (UVAM) and grinding (UVAG), with emphasis on their influence on the machinability, tool wear behavior and surface integrity. It also highlights the limitations of single-energy field UAM, such as inconsistent energy transmission and tool fatigue, leading to the increasing demand for multi-field techniques. Therefore, the advanced machining strategies, i.e., ultrasonic plasma oxidation-assisted grinding (UPOAG), protective coating-assisted cutting, and dual-field ultrasonic integration (e.g., ultrasonic-magnetic or ultrasonic-laser machining), were discussed in terms of their potential to further improve TiAl alloys processing. In addition, the importance of predictive force models in optimizing UAM processes was also highlighted, emphasizing the role of analytical and AI-driven simulations for better process control. Overall, this review underscores the ongoing evolution of UAM as a cornerstone of high-efficiency and precision manufacturing, while providing a comprehensive outlook on its current applications and future potential in machining TiAl alloys. Full article

An approach for the formation of intermetallic coatings on the titanium surface based on titanium aluminides is proposed. The approach involves producing a layered steel-aluminum-titanium metal composite via explosive welding, followed by heat treatment to form a diffusion zone at the steel–aluminum interface with a thickness of more than 30 μm, sufficient for the spontaneous separation of the steel layer. As a result, an aluminum layer approximately 0.3 mm thick remains on the titanium surface. Subsequent heating at temperatures of 700–850 °C, below the allotropic transformation temperature of titanium, results in the transformation of the aluminum layer into titanium aluminides. The formation of the intermetallic coating structure occurs as a result of the upward transportation of TiAl₃ fragments separated from the reaction zone by circulating melt flows. With increasing heat treatment time, these fragments become separated by the Al₂O₃ oxide phase. Full article

This work provides a comprehensive investigation into the synergistic effects of zirconium and oxygen on the microstructural evolution, high-temperature oxidation resistance, and mechanical properties of γ-phase Ti52AlxZr alloys (x = 0, 0.5, 1, and 2 at.%) under systematically controlled oxygen concentrations. Unlike prior studies that have examined these alloying elements in isolation, this study uniquely decouples the contributions of interstitial (oxygen) and substitutional (zirconium) solutes by employing low (LOx) and high (HOx) oxygen levels. Alloys were synthesized via vacuum arc melting and subsequently subjected to homogenization annealing at 1250 °C for 100 h to ensure phase and microstructural stability. Characterization techniques including scanning electron microscopy (SEM), X-ray diffraction (XRD), and electron backscatter diffraction (EBSD) were employed to elucidate phase constitution and grain morphology. Zirconium addition was found to stabilize the γ-TiAl matrix, suppress α₂-phase formation, and promote grain coarsening in LOx specimens. Conversely, elevated oxygen concentrations led to α₂-phase precipitation along grain boundaries. Mechanical testing, comprising Vickers hardness and uniaxial compression at ambient and elevated temperatures (800 °C), revealed that both zirconium and oxygen significantly enhanced strength and hardness, with Ti52Al2Zr delivering optimal mechanical performance. Moreover, zirconium substantially improved oxidation resistance by promoting the formation of a thinner, adherent Al₂O₃ scale while simultaneously inhibiting TiO₂ growth. Collectively, the findings demonstrate the critical role of zirconium in engineering advanced γ-TiAl-based intermetallics with superior high-temperature structural integrity and oxidation resistance. Full article

Titanium aluminides, particularly the Ti-48Al-2Cr-2Nb alloy, have drawn significant attention for their potential in high-temperature aerospace and automotive applications due to their exceptional performances and reduced density compared to nickel-based superalloys. However, their intermetallic nature poses challenges such as limited room-temperature ductility and fracture toughness, limiting their widespread application. Additive manufacturing, specifically Electron Beam Melting (EBM), has emerged as a promising method for producing complex-shaped components of titanium aluminides, overcoming challenges associated with conventional production methods. This work investigates the fracture behavior of Ti-48Al-2Cr-2Nb specimens with different microstructures, including duplex and equiaxed, under tensile and high-cycle fatigue at elevated temperatures. Fracture surfaces were analyzed to distinguish between static and dynamic fracture modes. A novel method, employing confocal microscopy acquisitions, is proposed to correlate surface roughness parameters with the causes of failure, offering new insights into the fracture mechanisms of titanium aluminides. The results reveal significant differences in roughness values between the propagation and fracture zones for all the temperatures and microstructure tested. At 650 °C, the crack propagation zone exhibits lower Sq values than the fracture zone, with the fracture zone showing more pronounced roughness, particularly for the equiaxed microstructure. However, at 760 °C, the difference in Sq values between the propagation and fracture zones becomes more pronounced, with a more substantial increase in Sq values in the fracture zone. These findings contribute to understanding fracture behavior in titanium aluminides and provide a predictive framework for assessing structural integrity based on surface characteristics. Full article

The present study focused on demonstrating the versatility of the slurry deposition technique to produce aluminide coatings to protect components from high-temperature corrosion in a broad temperature range, from 400 to 1400 °C. This is a simpler and low-cost coating technology used as an alternative to CVD and pack cementation, which also allows the coating of complex geometries and offers improved and simple repairability for a lot of industrial applications, along with avoiding the use of non-hazardous components. Slurry aluminide coatings from a proprietary water-based-Cr6+ free slurry were produced onto four different substrates: A516 carbon steel, 310H AC austenitic steel, Ti6246 Ti-based alloy and TZM, a Mo-based alloy. The resulting coatings were thoroughly characterised by FESEM and XRD, mainly so that the identification of microstructures and appropriate phases was reported for each coating. The importance of surface preparation and heat treatment as key parameters for the coating final microstructures was also evidenced, and how those parameters can be optimised to obtain stable intermetallic phases rich in Al to sustain the formation of a protective Al₂O₃ oxide scale. These coating systems have applications in diverse industrial environments in which high-temperature corrosion limits the lifetime of the components. Full article

Ti-Al intermetallics/TiB₂ composites were prepared from elemental powder mixtures by the method of self-propagating high-temperature synthesis (SHS). Reactant mixtures were formulated to contain two parts; one group was (2Ti + 4B) to form 2TiB₂ and the other group was (Ti + xAl) to produce Ti-Al intermetallic compounds. The content of Al ranged between x = 0.33 and 3.0, which was equivalent to the Ti/Al atomic ratio from Ti-25% Al to Ti-75% Al in the (Ti + xAl) group. The results showed that the increase of Al percentage reduced the overall combustion exothermicity and led to a slower self-sustaining combustion wave speed and a lower combustion temperature. Apparent activation energy of the Ti-Al-B solid-state combustion reaction was determined to be 114.7 kJ/mol by this study. Based on the XRD analysis, Ti-Al intermetallics/TiB₂ composites featuring Ti₃Al, TiAl, TiAl₂, and TiAl₃ as the dominant aluminide phase were respectively synthesized from the samples of Ti-25%~40% Al, Ti-50%~60% Al, Ti-71.4% Al, and Ti-75% Al. For the samples of Ti-25% Al and Ti-30% Al, Ti₃Al was the only aluminide formed. The microstructure of the composites exhibited that TiB₂ grains with a columnar shape of 2–3 μm in length were well distributed and embedded in the aluminide matrix. This study demonstrated an effective and energy-saving fabrication route for producing Ti-Al intermetallics/TiB₂ composites with different dominant aluminide phases. Full article

This article evaluates the fabrication technologies of titanium aluminide (Ti-Al) and its practical applications by comparing it with the well-known Ti-Al binary phase diagram and US patents. Meanwhile, by analyzing and discussing the various patented Ti-Al fabrication technologies and applications, this article discusses the applications of Ti-Al-based alloys, mainly in the aircraft field. The improved fabrication processes and new application technologies are under patent protection. These technologies are classified into six categories: basic research on Ti-Al-based alloys, powder metallurgy of Ti-Al-based alloys, casting and melting of Ti-Al-based alloys, PM and AM manufacturing methods for aircraft applications, other fabrication technologies by Ti-Al-based alloys, and self-propagating high-temperature synthesis (SHS) of Ti-Al-based alloys. By comparing the principles and characteristics of the above techniques, the advantages, disadvantages, and application fields of each are analyzed and their developments are discussed. Based on the characteristics of Ti-Al, new fabrication and application technologies can be developed, which can overcome the existing disadvantages and be used to form new aircraft components. Full article

Titanium aluminides are being explored as potential materials for the aeronautical sector. However, their application is limited by the high costs of processing and their difficulties in machining. This research evaluates the effectiveness of the minimum quantity lubrication technique (MQL) on the turning process of Ti48Al2Cr2Nb aluminide in terms of tool wear, tool life, cutting forces, surface integrity, and temperature. It was found that MQL conditions can improve the process efficiency, reducing the thermally induced wear mechanisms and enlarging the tool life compared to dry machining. Furthermore, it allows the cutting speed to be incremented, leading to lower processing times. However, MQL seems to not be effective in the reduction of the strain-hardening effect near the machined surface and, although the number of microcracks is reduced, defect-free surfaces cannot be obtained. Moreover, similar microstructural alterations as for dry cutting were detected. The best cutting conditions in terms of surface quality were assessed using the central composite face (CCF) design and surface response methodology. Optimization of the surface roughness under industrially viable cutting conditions was achieved with an average surface roughness value, Ra, of 0.29 µm (feed rate of 0.05 mm/rev, a cutting speed of 54.6 m/min and a depth of cut of 0.125 mm). Full article