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35 pages, 10077 KiB

Open AccessArticle

Optimizing the ECAP Parameters of Biodegradable Mg-Zn-Zr Alloy Based on Experimental, Mathematical Empirical, and Response Surface Methodology

by Majed O. Alawad, Abdulrahman I. Alateyah, Waleed H. El-Garaihy, Amal BaQais, Sally Elkatatny, Hanan Kouta, Mokhtar Kamel and Samar El-Sanabary

Materials 2022, 15(21), 7719; https://doi.org/10.3390/ma15217719 - 2 Nov 2022

Cited by 13 | Viewed by 1782

Abstract

Experimental investigations were conducted on Mg-3Zn-0.6Zr alloy under different ECAP conditions of number of passes, die angles, and processing route types, aimed at investigating the impact of the ECAP parameters on the microstructure evolution, corrosion behavior, and mechanical properties to reach optimum performance [...] Read more.

Experimental investigations were conducted on Mg-3Zn-0.6Zr alloy under different ECAP conditions of number of passes, die angles, and processing route types, aimed at investigating the impact of the ECAP parameters on the microstructure evolution, corrosion behavior, and mechanical properties to reach optimum performance characteristics. To that end, the response surface methodology (RSM), analysis of variance, second-order regression models, genetic algorithm (GA), and a hybrid RSM-GA were utilized in the experimental study to determine the optimum ECAP processing parameters. All of the anticipated outcomes were within a very small margin of the actual experimental findings, indicating that the regression model was adequate and could be used to predict the optimization of ECAP parameters. According to the results of the experiments, route Bc is the most efficient method for refining grains. The electrochemical impedance spectroscopy results showed that the 4-passes of route Bc via the 120°-die exhibited higher corrosion resistance. Still, the potentiodynamic polarization results showed that the 4-passes of route Bc via the 90°-die demonstrated a better corrosion rate. Furthermore, the highest Vicker’s microhardness, yield strength, and tensile strength were also disclosed by four passes of route Bc, whereas the best ductility at fracture was demonstrated by two passes of route C. Full article

(This article belongs to the Special Issue Forming Technologies and Mechanical Properties of Advanced Materials)

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13 pages, 7201 KiB

Open AccessArticle

Plastic Anisotropy Effect on Variation of Mechanical and Structural Properties of VT23 Titanium Alloy Subjected to Impact-Oscillatory Loading

by Mykola Chausov, Andrii Pylypenko, Pavlo Maruschak, Janette Brezinová, Jakub Brezina and Ihor Konovalenko

Materials 2022, 15(16), 5718; https://doi.org/10.3390/ma15165718 - 19 Aug 2022

Viewed by 1253

Abstract

The main regularities in the impact of varying intensity impact-oscillatory loading on the variation of the mechanical and structural properties of the VT23 high-strength two-phase transverse-rolled sheet titanium alloy have been found. The intensity of the impulse introduction of energy into the alloy [...] Read more.

The main regularities in the impact of varying intensity impact-oscillatory loading on the variation of the mechanical and structural properties of the VT23 high-strength two-phase transverse-rolled sheet titanium alloy have been found. The intensity of the impulse introduction of energy into the alloy under the dynamic non-equilibrium process (DNP) was estimated by ε_imp (the increment of dynamic strain). The pulse intensity was found to change the shape of the static strain diagram with further tensioning, as compared to the initial state. This indicates the effect from the structure self-organization inherent in the VT23 titanium alloy upon the DNP. After the DNP (ε_imp = 1.44%), with further static deformation, the tensile diagram revealed yield sites up to 6.5% long. In most cases, the DNP was found to have a negative effect on the variation of the mechanical properties of the VT23 titanium alloy, especially if the latter was rolled in the transverse direction. The optimal DNP intensity is ε_imp~1.5%. In this case, the DNP can be used as an effective plasticization technology for the VT23 titanium alloy (regardless of the rolling direction) in the stamping of high-strength titanium alloys. Changes in the mechanical and structural condition of the VT23 titanium alloy subjected to the DNP were confirmed by the fractographic investigation of specimen fractures. Full article

(This article belongs to the Special Issue Forming Technologies and Mechanical Properties of Advanced Materials)

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25 pages, 32526 KiB

Open AccessArticle

Optimizing the Thermomechanical Process of Nickel-Based ODS Superalloys by an Efficient Method

by Wuqiang He, Feng Liu, Liming Tan, Zhihui Tian, Zijun Qin, Lan Huang, Xiangyou Xiao, Guowei Wang, Pan Chen and Baogang Liu

Materials 2022, 15(12), 4087; https://doi.org/10.3390/ma15124087 - 9 Jun 2022

Viewed by 2003

Abstract

Thermo-mechanical process of nickel-based oxide dispersion strengthened (ODS) superalloys is critical to produce desired components. In this study, an efficient method of consolidating powder is introduced to optimize the preparation process, microstructure and properties of nickel-based ODS superalloys. The influences of consolidation temperature, [...] Read more.

Thermo-mechanical process of nickel-based oxide dispersion strengthened (ODS) superalloys is critical to produce desired components. In this study, an efficient method of consolidating powder is introduced to optimize the preparation process, microstructure and properties of nickel-based ODS superalloys. The influences of consolidation temperature, strain rate and ball milling time on the hardness of nickel-based superalloys were studied. The relationship among process, microstructure and hardness was established, the nanoparticles strengthening and grain boundary strengthening in nickel-based ODS superalloys were discussed. The results indicate that long ball milling time, moderately low consolidation temperature and high strain rates are beneficial to improving properties of nickel-based superalloys. Moreover, dispersion strengthening of nanoparticles and grain boundary strengthening play important roles in enhancing nickel-based ODS superalloys. Full article

(This article belongs to the Special Issue Forming Technologies and Mechanical Properties of Advanced Materials)

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14 pages, 8884 KiB

Open AccessArticle

Numerical and Experimental Analysis of Titanium Sheet Forming for Medical Instrument Parts

by Wojciech Więckowski, Maciej Motyka, Janina Adamus, Piotr Lacki and Marcin Dyner

Materials 2022, 15(5), 1735; https://doi.org/10.3390/ma15051735 - 25 Feb 2022

Cited by 7 | Viewed by 2335

Abstract

The paper analyses the forming of the surgical instrument handles made of Grade 2 titanium sheets. Sheet metal forming is a technology ensuring high strength and light weight of products. Replacing stainless steels with titanium further reduces instrument weight and additionally provides the [...] Read more.

The paper analyses the forming of the surgical instrument handles made of Grade 2 titanium sheets. Sheet metal forming is a technology ensuring high strength and light weight of products. Replacing stainless steels with titanium further reduces instrument weight and additionally provides the required resistance to corrosive environments typical for surgeries. The low instrument weight is important to prevent fatigue of surgeons and allow them to maintain high operational accuracy during long term surgeries. The numerical analysis of the technological process was performed in order to adapt it to forming tool handles using titanium sheets instead of steel sheets. The numerical calculations were experimentally verified. It was found that, in the case of titanium handles, it is necessary to use a blank holder in the first forming operation to eliminate sheet wrinkling in the flange area. The shape and dimensional accuracy of the drawn part after trimming were high enough and the 4th forming operation became unnecessary. Moreover, the process modification included lubrication using rapeseed oil with the addition of boric acid, which effectively prevents the galling of titanium on the working surfaces of the steel tools and ensures a more uniform distribution of plastic strains in the drawn part. Full article

(This article belongs to the Special Issue Forming Technologies and Mechanical Properties of Advanced Materials)

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9 pages, 2167 KiB

Open AccessCommunication

Investigation of the Size Effects on the Elongation of Ti-2.5Al-1.5Mn Foils with Digital Image Correlation Method

by Chunju Wang, Weiwei Zhang and Zhenwu Ma

Materials 2021, 14(23), 7353; https://doi.org/10.3390/ma14237353 - 30 Nov 2021

Viewed by 1257

Abstract

The increasing demand for parts with a large specific surface area such as fuel panels has put forward higher requirements for the plasticity of foils. However, the deformation characteristics of foils is hard to be illustrated in-depth due to their very short deformation [...] Read more.

The increasing demand for parts with a large specific surface area such as fuel panels has put forward higher requirements for the plasticity of foils. However, the deformation characteristics of foils is hard to be illustrated in-depth due to their very short deformation process. In this paper, the digital image correlation method was applied to investigate the influence of size effect on the elongation of Ti-2.5Al-1.5Mn foils. The results showed that the elongation of Ti-2.5Al-1.5Mn foils increased with the decrease in the ratio of thickness-to-grain diameter (t/d value). Then, the macro deformation distribution of foils was analyzed, combined with their microstructure characteristics, and it was found that the increasing influence of individual grain heterogeneity leads to the earlier formation of a concentrated deformation zone, which changes the deformation mode of foils. The concentrated deformation increases with the decrease in t/d value, thus dominating the trend of the foil elongation. Furthermore, the homogeneous deformation and concentrated deformation can be divided into two different zones by a certain critical t/d value. These results provide a basis for understanding and further exploration of the deformation behavior of titanium foils. Full article

(This article belongs to the Special Issue Forming Technologies and Mechanical Properties of Advanced Materials)

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21 pages, 4525 KiB

Open AccessArticle

Optimization Method of Tool Parameters and Cutting Parameters Considering Dynamic Change of Performance Indicators

by Daxun Yue, Anshan Zhang, Caixu Yue, Xianli Liu, Mingxing Li and Desheng Hu

Materials 2021, 14(20), 6181; https://doi.org/10.3390/ma14206181 - 18 Oct 2021

Cited by 5 | Viewed by 1716

Abstract

In the process of metal cutting, the cutting performance of cutting tools varies with different parameter combinations, so the results of the performance indicators studied are also different. So in order to achieve the best performance indicator it is necessary to get the [...] Read more.

In the process of metal cutting, the cutting performance of cutting tools varies with different parameter combinations, so the results of the performance indicators studied are also different. So in order to achieve the best performance indicator it is necessary to get the best parameter matching combination. In addition, in the process of metal cutting, the value of the performance index is different at each stage of the processing process. In order to consider the cutting process more comprehensively, it is necessary to use a comprehensive evaluation method that can evaluate the dynamic process of performance indicators. This paper uses a dynamic evaluation method that considers the dynamic change of performance indicators in each stage of the cutting process to comprehensively evaluate the tool parameters and cutting parameters at each level. For the purpose of high processing efficiency and long tool life, tool wear rate and material removal rate are used as performance indicators. In the case of specified rake angle, cutting speed and cutting width, titanium alloy is studied by end milling cutter side milling. The tool parameters and cutting parameters in milling process are optimized by using a dynamic comprehensive evaluation method based on gain horizontal excitation. Finally, the parameter matching combination that can make the performance indicator reach the best is obtained. The results show that when the rake angle is 8°, the cutting speed is 37.68 m/min, and the cutting width is 0.2 mm, the tool wear rate and material removal rate are the best when the clearance angle is 9°, the helix angle is 30°, the feed per tooth is 0.15 mm/z, and the cutting depth is 2.5 mm. Full article

(This article belongs to the Special Issue Forming Technologies and Mechanical Properties of Advanced Materials)

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22 pages, 11559 KiB

Open AccessArticle

Statistical Analysis and Optimisation of Data for the Design and Evaluation of the Shear Spinning Process

by Sandra Puchlerska, Krzysztof Żaba, Jarosław Pyzik, Tomasz Pieja and Tomasz Trzepieciński

Materials 2021, 14(20), 6099; https://doi.org/10.3390/ma14206099 - 15 Oct 2021

Cited by 4 | Viewed by 1483

Abstract

This work proposes a research method that is a scheme that can be universally applied in problems based on the selection of optimal parameters for metal forming processes. For this purpose, statistical data optimisation methods were used. The research was based on the [...] Read more.

This work proposes a research method that is a scheme that can be universally applied in problems based on the selection of optimal parameters for metal forming processes. For this purpose, statistical data optimisation methods were used. The research was based on the analysis of the shear spinning tests performed in industrial conditions. The process of shear spinning was conducted on the components made of Inconel 625 nickel superalloy. It was necessary to select the appropriate experimental plan, which, by minimising the number of trials, allowed one to draw conclusions on the influence of process parameters on the final quality of the product and was the starting point for their optimisation. The orthogonal design

2_{III}^{3 - 1}

is the only design for three factors at two levels, providing non-trivial and statistically significant information on the main effects and interactions for the four samples. The samples were analysed for shape and dimensions using an Atos Core 200 3D scanner. Three-dimensional scanning data allowed the influence of the technological parameters of the process on quality indicators, and thus on the subsequent optimisation of the process, to be determined. The methods used proved to be effective in the design, evaluation and verification of the process. Full article

(This article belongs to the Special Issue Forming Technologies and Mechanical Properties of Advanced Materials)

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Review

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36 pages, 116056 KiB

Open AccessReview

Single-Point Incremental Forming of Titanium and Titanium Alloy Sheets

by Valentin Oleksik, Tomasz Trzepieciński, Marcin Szpunar, Łukasz Chodoła, Daniel Ficek and Ireneusz Szczęsny

Materials 2021, 14(21), 6372; https://doi.org/10.3390/ma14216372 - 25 Oct 2021

Cited by 27 | Viewed by 3659

Abstract

Incremental sheet forming of titanium and its alloys has a significant role in modern manufacturing techniques because it allows for the production of high-quality products with complex shapes at low production costs. Stamping processes are a major contributor to plastic working techniques in [...] Read more.

Incremental sheet forming of titanium and its alloys has a significant role in modern manufacturing techniques because it allows for the production of high-quality products with complex shapes at low production costs. Stamping processes are a major contributor to plastic working techniques in industries such as automotive, aerospace and medicine. This article reviews the development of the single-point incremental forming (SPIF) technique in titanium and its alloys. Problems of a tribological and microstructural nature that make it difficult to obtain components with the desired geometric and shape accuracy are discussed. Great emphasis is placed on current trends in SPIF of difficult-to-form α-, α + β- and β-type titanium alloys. Potential uses of SPIF for forming products in various industries are also indicated, with a particular focus on medical applications. The conclusions of the review provide a structured guideline for scientists and practitioners working on incremental forming of titanium and titanium alloy sheets. One of the ways to increase the formability and minimize the springback of titanium alloys is to treat them at elevated temperatures. The main approaches developed for introducing temperature into a workpiece are friction heating, electrical heating and laser heating. The selection of an appropriate lubricant is a key aspect of the forming process of titanium and its alloys, which exhibit unfavorable tribological properties such as high adhesion and a tendency to adhesive wear. A review of the literature showed that there are insufficient investigations into the synergistic effect of rotational speed and tool rotation direction on the surface roughness of workpieces. Full article

(This article belongs to the Special Issue Forming Technologies and Mechanical Properties of Advanced Materials)

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