Search Results (109)

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

Maintaining a consistent quality of TiAl4822 blades used in jet engines is crucial, even when compositional variations occur during production. This study investigates the optimal Al and O concentration ranges that yield favorable practical properties. Additionally, the feasibility of reusing machining chips as a low-cost melting feedstock is explored. The results indicate that both impact resistance at 25 °C and machinability remain unaffected or even improve at O concentrations up to at least 0.13 wt%. Moreover, materials containing 0.13 wt% O exhibit the widest optimal range of Al concentrations (46.8–47.4 at%), but was narrower at lower or higher Al concentrations. The influence of the α₂-phase ratio on impact resistance is substantially greater than that of O concentration, with the optimal range being 0.2–0.3. Furthermore, a new pre-treatment method is developed to reuse machining chips containing large amounts of water-soluble cutting oil. This method involves removing C through atmospheric heating after ultrasonic cleaning using acetone. Furthermore, TiAl4822 castings including these preprocessed chips exhibit superior properties compared with those of chip-free low-O materials, despite the higher O concentration. These findings demonstrate that moderate O enrichment is tolerable, and even beneficial, enabling cost-effective recycling in TiAl4822 blade production. 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

B is considered a valuable additive for TiAl alloys, because it is believed to improve their properties by refining their microstructures. However, the effects of B on the practical properties of TiAl alloys for jet engine blades and the optimal addition amount for achieving balanced properties remain unclear. Specifically, there have been very few studies to date in which the practical properties of alloys have been evaluated across a wide range of B addition levels. Therefore, we evaluated various reliability, cost, and performance properties of jet engine blade materials using cast Ti-45,47Al-2Nb-2Mn (the same as XD alloys), with varying B addition levels. The results showed that, in some cases, low B addition levels (0.1–0.2 at.%) could enhance the impact resistance and high-cycle fatigue performance. However, even low B addition levels negatively impacted the machinability, castability, and creep strength. Further, adding 0.4 B or more significantly reduced most practical properties. Compared to XD alloys, TiAl4822 exhibited a superior balance, which is attributed to the higher B content (1 at.%) in XD alloys and the greater effectiveness of Cr relative to Mn in improving the alloy’s high-temperature impact resistance. 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

This study facilitates the data-driven design of novel cast TiAl alloys by systematically investigating the critical elements and their interactions affecting room-temperature (RT) tensile properties by the machine learning method based on SHAP analysis. Comparative analysis of three algorithms within the training dataset proved the random forest regression (RFR) as the optimal modeling approach. To evaluate model performance and prevent overfitting, leave-one-out cross-validation (LOOCV) was simultaneously implemented during training. All the three well-trained models demonstrated robust predictive capabilities for ultimate tensile strength (UTS), elongation (EL), and yield strength (YS). Detailed investigation on both the magnitude and directionality of feature importance and interaction disclosed distinct elemental influences: B, C, and Nb predominantly improved UTS and YS, while Cr, Mn, and Al positively affected EL. The highly probable direction of feature interaction between two different elements on the RT tensile properties of cast TiAl alloys was basically revealed. Notably, Al–B interactions enhance UTS at Al < 45.5 at%; Cr–Mn synergistically improves EL when Cr > 1 at%; both Al–B and Al–C interactions boost YS within 44–46 at% Al. Despite a slight distinction in casting technology, this research established a qualitative relationship between the chemical elements and the RT tensile properties of TiAl alloys, providing design recommendations for cast TiAl alloys with excellent RT tensile properties. Full article

Scaling up the production of TiAl turbine wheels for passenger car turbochargers requires the fabrication of thin blades that are similar to those of nickel-based superalloys. To achieve this, the molten metal fillability and impact resistance of thin blades must be improved. In this study, the effects of composition on these properties are predicted using simple laboratory experiments with binary, ternary, and practical alloys and are then verified with actual turbine wheels. The melt fillability of the turbine wheel blade is predicted using the amount of molten metal passing through an Al₂O₃-1%SiO₂ mesh. The binary alloy exhibits the best fillability, which is reduced by the addition of Cr and Si. Charpy impact tests on as-cast materials at 25 and 850 °C show that the addition of Cr and Mn improves the impact resistance, but the addition of Nb, W, Mo and Si reduces it. Therefore, the molten metal fillability and/or impact resistance of practical TiAl alloys containing such additives owing to other requirements are low and require improvement for use in thin-blade turbine wheel applications. Full article

In this study, the ProCast software (version 2014) incorporating the CAFE model is applied to conduct numerical simulation analysis of the directional solidification process of titanium–aluminium alloy cylindrical rods at varying withdraw rates. According to the analytical results, the withdraw rate is a critical parameter that affects the morphology of the solid–liquid interface and the grain growth behavior during the directional solidification process. An increase in the drawing rate facilitates nucleation undercooling within the rod, inducing a shift in grain morphology from columnar to equiaxed. At a drawing rate of 1 mm/min, the solid–liquid interface exhibits the most stable morphology, as characterized by a flat interface. As indicated by further analysis, at this drawing rate, specific grain orientations are eliminated during competitive growth with an increase in solid fraction, culminating in the formation of columnar grain structures. Additionally, the impact of drawing rate on grain size and number is investigated, with an increase observed in grain number with drawing rate and a decrease found in grain size. The findings of this study contribute to a deeper understanding of mechanisms behind the grain morphology evolution of titanium aluminide, providing crucial theoretical support for optimizing directional solidification processes. Full article

TiC-based cermet clads were applied onto high-Cr-containing, cold work D2 tool steel substrates through laser-directed energy deposition (L-DED). A novel suspension-based preplacement method was used to apply the feedstock prior to laser cladding. The preplaced material was then subjected to laser processing using various laser powers (200 to 350 W) and scanning speeds (58 to 116 mm/min.), resulting in the fabrication of high-density clads on the substrates. Hardness profiles were generated by cross-sectional micro-indentation of the clad layers. Micro-Vickers hardness (HV) values of the cermet clads were measured from load–displacement curves under a range of applied normal forces, which are in the range of 265.7 to 890.3 HV. As a preliminary assessment of the wear response, a variety of single-pass scratch testing approaches were undertaken. A qualitative evaluation of ‘interface’ mechanics between the ‘clad’ and substrate material was also performed by cross-sectional scratching of the clads; as a chemical clad is developed, this effectively is assessing the transitions through the clad microstructure. Failure modes and damage mechanism were examined at different processing parameters by means of acoustic emission (AE) and coefficient of friction (COF) measurements, together with assessment of the post-test microstructures. The scratch hardness (H_Sp) of the cermet clads varied within the range of 4.88 to 7.58 GPa, as a function of applied normal force (ranged within 10–40 N), which was considerably higher than the D2 substrate (H_Sp = 3 GPa). Full article