Tensile behavior of Ti-6Al-4V alloy fabricated by selective laser melting: effects of microstructures and as-built surface quality

Selective laser melting(SLM) is a powerful additive manufacturing(AM) technology, of which the most prominent advantage is the ability to produce components with a complex geometry. The service performances of the SLM-processed components depend on the microstructure and surface quality. In this work, the microstructures, mechanical properties, and fracture behaviors of SLM-processed Ti-6 Al-4 V alloy under machined and as-built surfaces after annealing treatments and hot isostatic pressing(HIP) were investigated. The microstructures were analyzed by optical microscope(OM), scanning electron microscope(SEM) and transmission electron microscopy(TEM). The mechanical properties were measured by tensile testing at room temperature. The results indicate that the as-deposited microstructures are characterized by columnar grains and fine brittle martensite and the asdeposited properties present high strength, low ductility and obvious anisotropy. After annealing at 800-900°C for 2-4 h and HIP at 920°C/100 MPa for 2 h, the brittle martensite could be transformed into ductile lamellar(α+β) microstructure and the static tensile properties of SLM-processed Ti-6 Al-4 V alloys in the machined condition could be comparable to that of wrought materials. Even after HIP treatment, the as-built surfaces could decrease the ductility and reduction of area of SLM-processed Ti-6 Al-4 V alloys to 9.2% and 20%, respectively. The crack initiation could occur at the columnar grain boundaries or at the as-built surfaces. The lamellar(α+β) microstructures and columnar grains could hinder or distort the crack propagation path during tensile tests.

Effects of normal stress, surface roughness, and initial grain size on the microstructure of copper subjected to platen friction sliding deformation

The effects of applied normal stress, surface roughness, and initial grain size on the microstructure of pure Cu developed during platen friction sliding deformation （PFSD） processing were investigated. In each case, the deformation microstructure was characterized and the hardness of the treated surface layer was measured to evaluate its strength. The results indicated that the thickness of the deformed layer and the hardness at any depth increased with increasing normal stress. A smaller steel platen surface roughness resulted in less microstruc- tural refinement, whereas the microstructural refinement was enhanced by decreasing the surface roughness of the Cu sample. In the case of a very large initial grain size （d 〉 10 mm）, a sharper transition from fine-grain microstructure to undeformed material was obtained in the treated surface layer after PFSD processing.

Hierarchical microstructures with high spatial frequency laser induced periodic surface structures possessing different orientations created by femtosecond laser ablation of silicon in liquids

High spatial frequency laser induced periodic surface structures(HSFLs)on silicon substrates are often developed on flat surfaces at low fluences near ablation threshold of 0.1 J/cm2,seldom on microstructures or microgrooves at relatively higher fluences above 1 J/cm^2.This work aims to enrich the variety of HSFLs-containing hierarchical microstructures,by femtosecond laser(pulse duration:457 fs,wavelength:1045 nm,and repetition rate:100 kHz)in liquids(water and acetone)at laser fluence of 1.7 J/cm^2.The period of Si-HSFLs in the range of 110–200 nm is independent of the scanning speeds(0.1,0.5,1 and 2 mm/s),line intervals(5,15 and 20μm)of scanning lines and scanning directions(perpendicular or parallel to light polarization direction).It is interestingly found that besides normal HSFLs whose orientations are perpendicular to the direction of light polarization,both clockwise or anticlockwise randomly tilted HSFLs with a maximal deviation angle of 50°as compared to those of normal HSFLSs are found on the microstructures with height gradients.Raman spectra and SEM characterization jointly clarify that surface melting and nanocapillary waves play important roles in the formation of Si-HSFLs.The fact that no HSFLs are produced by laser ablation in air indicates that moderate melting facilitated with ultrafast liquid cooling is beneficial for the formation of HSFLs by LALs.On the basis of our findings and previous reports,a synergistic formation mechanism for HSFLs at high fluence was proposed and discussed,including thermal melting with the concomitance of ultrafast cooling in liquids,transformation of the molten layers into ripples and nanotips by surface plasmon polaritons(SPP)and second-harmonic generation(SHG),and modulation of Si-HSFLs direction by both nanocapillary waves and the localized electric field coming from the excited large Si particles.

Microstructure and properties of Fe-based coatings on cutting pick surface formed by plasma jet surface metallurgy

The Fe-based composite coatings were produced on the attrition spot of cutting pick by plasma jet surface metallurgy, and metallurgical bonding was obtained between coating and substrate. The results show that the microstructure, microhardness, wear resistance and erode resistance of the coating are all evaluated. The coating has apparent characteristics of rapid and layered crystallization from planar crystal-cell/dendritic transition zone on the interface, to equiaxed crystal on the midst, to spike crystal on the surface. The microhardness gradually increases from the bottom to the top of the coating. The composite coating has better wear resistance and erode resistance compared to steel substrate.

Microstructure and property modifications in surface layers of a Mg-4Sm-2Al-0.5Mn alloy induced by pulsed electron beam treatments

In this work,surface modification of a Mg-4Sm-2Al-0.5Mn alloy with high current pulse electron beam(HCPEB)under different number of pulses were investigated.The evolution in microstructure,composition and phase components and properties in the surface layer before and after HCPEB treatment were characterized.It was found that the Al 11 Sm 3 and Al 2 Sm phases in the surface layer were gradually dissolved during HCPEB treatment,leading to the formation of a chemical homogeneous melted layers.Besides,deformation bands were formed in the treated layer due to the thermal stress generated during treatment.After 15 pulses treatment,the surface hardness increases to the maximum value of about 62.2 HV,about 61.2%higher than that of the untreated state.Electrochemical results show that the 15 pulses treated sample presents the best corrosion resistance in the 3.5wt%NaCl water solution by showing the highest corrosion potential(E_(corr))of-1.339V SEC and the lowest corrosion current density(I_(corr))of 1.48×10^(-6)A·cm^(-2).The results prove that the surface properties of the Mg-4Sm-2Al-0.5Mn alloy can be significantly improved by the HCPEB treatments under proper conditions.

Microstructure of Ni /WC Surface Composite Layer on Gray Iron Substrate

The surface infiltrated composite （Ni/WC） layers on gray iron substrate were fabricated through a vacuum infiltration casting technique （VICT） using Ni-based composite powder with different WC particles content as raw materials.The microstructures of surface infiltrated composite layer,the interface structures between surface composite layer and the substrate,the changes of macro-hardness with the increasing of WC content and the micro-hardness distribution are investigated.The infiltrated composite layer includes a surface composite layer and a transition layer,and the thickness of the transition layer decreases with the increasing content of WC.The thickness of transition layer with 20%WC content in the surface infiltrated composite layer was 170 μm which was the thickest for all transition layers with different WC content.The surface composite layer was mainly composed of WC,W2C,FeB and NiB,along with Ni-Cr-Fe,Ni （Cr） solid solution,Ni （Si） solid solution and Ni （Fe） solid solution.The transition layer was composed of Ni （Cr） solid solution,Ni （Fe） solid solution,Ni （Si） solid solution,Fe （Ni） solid solution and eutectic.The surface macro-hardness and micro-hardness of the infiltrated layer had been evaluated.The macro-hardness of the surface composite layer decreases with the WC content increasing,and the average macro-hardness is HRC60.The distribution of micro-hardness presents gradient change.The average micro-hardness of the infiltrated layer is about HV1000.

EVOLUTION OF MICROSTRUCTURE OF LASER SURFACE ALLOYING OF γ TiAi ALLOY WITH NITROGEN

Laser surface alloying of γ TiAl alloy with nitrogen was studied under the constant protective nitrogen current (20l /min). The experimental results shown that the surface multi layers formed with experimental parameters could be up to 600μm depth; it consists of TiN,Ti 2AlN,α 2 and γ phases, without AlN, and the irregular coarse continuous “flow” line,dendrite,needle and granular nitrides disperse on the fine dendrite casting α 2 and γ phases substrate. The microstructure and compositions in the nitiding layer were determined and analyzed by SEM and EPMA and the mechanism for the formation of microstructure in the nitriding layer was also discussed.

Effect of RE on Cracking Resistance and Microstructure of Coatings Formed by Plasma Jet Surface Metallurgy

Metallurgical coatings of iron-based alloy with RE oxide were prepared on low-carbon steel using a home-made DC-plasma jet surface metallurgy equipment. Scanning electron microscope (SEM), energy dispersive X-ray (EDX) microanalysis and X-ray diffraction analysis (XRD) were employed to observe the microstructure and analyze the chemical compositions of coatings. And the cracking susceptibility of coatings was studied in terms of RE addition. Experimental results show that addition of RE oxide (La_2O_3 and CeO_2) can refine and purify the microstructure, and can reduce the cracking susceptibility of coatings.

Surface Microstructure Characterization of Sol-gel Derived Porous TiO_2 Thin Films

Porous TiO2 thin films were prepared from alkoxide solutions with and without polyethylene glycol (PEG) by sol-get route on soda lime glass, and were characterized by atomic force microscopy (AFM), transmission electron microscopy (TEM) and X-ray diffraction (XRD). The results show that TiO2 film prepared from precursor solution without PEG is composed of spherical particles of about 100 nm and several nanometer mesoporous pores. With the increase of the amount of PEG added to the precursor solution, the diameter and the depth of the pores in the resultant films increas on the decomposition of PEG during heat-treatment, which lead to them increase of the surface roughness of the films. XRD and TEM results show that the single anatase phase is precipitated and there are some orientation effects in (101) direction.

Study on microstructure and properties of laser surface melted layer of AZ31B magnesium alloy

An attempt has been made to improve the surface properties of AZ31B magnesium alloy through solid solution hardening and refinement of microstructures using a CO2 laser as a heat generating source. X-ray diffraction （XRD） was used to identify the phases. Microstructure and properties of laser melted layer of AZ31B magnesium alloy were observed or tested by means of optical microscope （OM）, scanning electron microscope （SEM）, micro-hardness equipment and electrochemical corrosion equipment etc. The results show that the microstructure of laser melted layer becomes finer significantly and uniform. Compared with the substrate, the content of β-Mg17 Al12 phase of melted layer decreases comparatively. Microhardness of the laser melted layer is improved to 50 -95 HV0. 05 as compared to 40 -45 HV0.05 of the AZ31B Mg alloy substrate. The results of electrochemical corrosion show that the corrosion resistance of laser surface melted layer has been improved.

Investigation of the Relation between Rolling Contact Fatigue Property and Microstructure on the Surface Layer of D2 Wheel Steel

Through the rolling contact fatigue experiment under the condition of the lubricating oil, this article investigated the relation between contact fatigue property and microstructure on the surface layer of D2 wheel steel. The results showed that although the roughness of the original specimen induced by mechanical processing would diminish to some extent in the experiment, the 0.5 - 1.5 μm thick layer of ultrafine microstructure on the original mechanically-processed specimen surface would still become micro-cracks and small spalling pits due to spalling, and would further evolve into fatigue crack source. Additionally, even under the impact of the load that was not adequate to make the material reach fatigue limit, the ferrite in the microstructure underwent plastic deformation, which led the refinement of proeutectoid ferrite grains. During the experiment, the hardening and the refinement caused by plastic deformation consisted with the theory that dislocation gave rise to plastic deformation and grain refinement. The distribution laws of hardness and ferrite grain sizes measured could be explained by the distribution law of the shearing stress in the subsurface.

Effect of the surface microstructure of arsenopyrite on the attachment of Sulfobacillus thermosulfidooxidans in the presence of dissolved As(Ⅲ)

Understanding bacterial adsorption and the evolution of biofilms on arsenopyrite with different surface structures is of great signific-ance to clarifying the mechanism of microbe-mineral interfacial interactions and the production of acidic mine drainage impacting the environ-ment.In this study,the attachment of Sulfobacillus thermosulfidooxidans cells and subsequent biofilm formation on arsenopyrite with different surface structures in the presence of dissolved As(Ⅲ)was studied.Arsenopyrite slices with a specific surface were obtained by electrochemic-al corrosion at 0.26 V.The scanning electronic microscopy-energy dispersion spectra analyses indicated that the arsenopyrite surface deficient in sulfur and iron obtained by electrochemical treatment was not favorable for the initial adsorption of bacteria,and the addition of As(Ⅲ)in-hibited the adsorption of microbial cells.Epifluorescence microscopy showed that the number of cells attaching to the arsenopyrite surface in-creased with time;however,biofilm formation was delayed significantly when As(Ⅲ)was added.

Effects of Sintering Atmosphere on the Microstructure and Surface Properties of Symmetric TiO2 Membranes

The effects of sintering atmosphere on the properties of symmetric TiO2 membranes are studied with regard to sintering behavior,porosity,mean pore size,surface composition,and surface charge properties.The experimental results show that the symmetric TiO2 membranes display better sintering activity in the air than in argon,and the mean pore diameters and porosities of the membrane sintered in argon are higher than those of the membrane sintered in the air at the same temperature.The surface compositions of the symmetric TiO2 membrane sintered in the air and in argon at different temperatures,as studied by X-ray photoelectron spectroscopy,are discussed in terms of their chemical composition,with particular emphasis on the valence state of the titanium ions.The correlation between the valence state of the titanium ions at the surface and the surface charge properties is examined.It is found that the presence of Ti 3+,introduced at the surface of the symmetric TiO2 membranes by sintering in a lower partial pressure of oxygen,is related to a significant decrease in the isoelectric point.TiO2 with Ti 4+ at the interface has an isoelectric point of 5.1,but the non-stoichiometric TiO2-x with Ti 3+ at the interface has a lower isoelectric point of 3.6.

Influence of Al_2O_3 particles on the microstructure and mechanical properties of copper surface composites fabricated by friction stir processing

The influence of three factors, such as volume percentage of reinforcement particles(i.e. Al2O3), tool tilt angle and concave angle of shoulder, on the mechanical properties of Cue Al2O3 surface composites fabricated via friction stir processing was studied. Taguchi method was used to optimize these factors for maximizing the mechanical properties of surface composites. The fabricated surface composites were examined by optical microscope for dispersion of reinforcement particles. It was found that Al2O3 particles are uniformly dispersed in the stir zone. The tensile properties of the surface composites increased with the increase in the volume percentage of the Al2O3 reinforcement particles.This is due to the addition of the reinforcement particles which increases the temperature of recrystallization by pinning the grain boundaries of the copper matrix and blocking the movement of the dislocations. The observed mechanical properties are correlated with microstructure and fracture features.

Casting of microstructured shark skin surfaces and possible applications on aluminum casting parts

Within the project "Functional Surfaces via Micro-and Nanoscaled Structures" which is part of the Cluster of Excellence "Integrative Production Technology" established and financed by the German Research Foundation (DFG),an investment casting process to produce 3-dimensional functional surfaces down to a structural size of 1μm on near-net-shape-casting parts has been developed.The common way to realize functional microstructures on metallic surfaces is to use laser ablation,electro discharge machining or micro milling.The handicap of these processes is their limited productivity.The approach of this project to raise the efficiency is to use the investment casting process to replicate microstructured surfaces by moulding from a laser-microstructured grand master pattern.The main research objective deals with the investigation of the single process steps of the investment casting process with regard to the moulding accuracy.Actual results concerning making of the wax pattern,suitability of ceramic mould and core materials for casting of an AlSi7Mg0.3 alloy as well as the knock-out behavior of the shells are presented.By using of the example of an intake manifold of a gasoline race car engine,a technical shark skin surface has been realized to reduce the drag of the intake air.The intake manifold consists of an air-restrictor with a defined inner diameter which is microstructured with technical shark skin riblets.For this reason the inner diameter cannot be drilled after casting and demands a very high accuracy of the casting part.A technology for the fabrication and demoulding of accurate microstructured castings are shown.Shrinkage factors of different moulding steps of the macroscopic casting part as well as the microscopic riblet structure have been examined as well.

Effects of size reduction on deformation,microstructure,and surface roughness of micro components for micro metal injection molding

The fabrication of 17-4PH micro spool mandrils by micro metal injection molding was described here. The effects of size reduction on deformation, microstructure and surface roughness were studied by comparing a I center dot 500 mu m micro post and a I center dot 1.7 mm cylinder after debinding and sintering. Experimental results show that slumping of the micro posts occurred due to a dramatic increase in outlet vapor pressure initiated at the thermal degradation onset temperature and the moment of gravity. Asymmetrical stress distribution within the micro component formed during the cooling stage may cause warping. Prior solvent debinding and adjustment in a thermal debinding scheme were useful for preventing the deformation of the micro components. Smaller grain size and higher micro hardness due to impeded grain growth were observed for the micro posts compared with the I center dot 1.7 mm cylinder. Surface roughness increased with distance from the gate of the micro spool mandril due to melt front advancement during mold filling and the ensuing pressure distribution. At each position, surface roughness was dictated by injection molding and increased slightly after sintering.

Effects of the microstructure of twin roll cast and hot rolled plates on the surface quality of presensitized plates

The effect of the microstructure of plates fabricated both in the traditional process, involving casting, hot rolling and cold rolling （HR）, and in the novel twin roll casting ＋ cold rolling （TRC） process on the surface quality of presensitized （PS） plates was analyzed by optical microscopy （OM）, scanning electron microscopy （SEM）, and energy-dispersive X-ray spectroscopy （EDXS）. The formation of pores on the surface of the electrolyzed HR plate could be attributed to the presence of approximately 1-μm-sized large Al-Fe precipitates in the HR plate compared to the smaller precipitates in the TRC plate. Moreover, residual graphite lubricants used during the TRC process were entrapped on the surface of the TRC plate during the subsequent rolling process. The entrapped pollutants tended to further deteriorate the formation of pores on the surface of the TRC plate, and no residual carbon was detected on the surface of the HR plate. Furthermore, the surface quality of the TRC plate can be improved by surface cleaning before the cold rolling process, which could dramatically lower the residual graphite on the surface.

Formation of surface-attached microstructured polyelectrolyte brushes

Surface-attached micropattemed polyelectrolyte brushes on planar solid surfaces are generated using free radical polymerization photo-initiated by self-assembled initiator monolayers. It is shown that the formed patterns can be either negative or positive with different patterning processes.

Study on microstructure of Fe-Cr-C-Ni-B-Si coating formed by plasma jet surface metallurgy

The technical connotation of surface metallurgical technology by DC-Plasma-Jet is a kind of rapid, non- equilibrium metallurgical process which is similar to powder metallurgy. Accordingly the specialized equipment is developed all by ourselves, which is not subjected to limitation of solubility, melting point, density of constituents, therefore pre-alloy powders are not needed. The plasma surface metallurgical coating using Fe-Cr-C-Ni-B-Si mixed alloy powders has good wettability with substrate material. The metallurgical coating has apparent characteristics of rapid and layered crystallization from planar crystal-cell to dendritic transition zone at the interface, from dendritic crystal to equiaxed crystal in the midst, from equiaxed crystal to spike crystal on the surface. Its metastable microstructure is complex phase of supersaturated γ- （ Fe, Ni ） dendritic crystal solutioning great amount of alloy element and interdendritic eutectic structure （ Cr, Fe） γ （ C, B） 3 and T-（Fe,Ni）.

Microstructure and high-temperature wear properties of in situ TiC composite coatings by plasma transferred arc surface alloying on gray cast iron

In this work, an in situ synthesized TiC-reinforced metal matrix composite （MMC） coating of approximately 350-400μm thickness was fabricated on a gray cast iron （GCI） substrate by plasma transferred arc （PTA） surface alloying of Ti-Fe alloy powder. Microhard- ness tests showed that the surface hardness increased approximately four-fold after the alloying treatment. The microstructure of the MMC coating was mainly composed of residual austenite, acicular martensite, and eutectic ledeburite. Scanning electron microscopy （SEM） and X-ray diffraction analyzes revealed that the in situ TiC particles, which were formed by direct reaction of Ti with carbon originally contained in the GCI, was uniformly distributed at the boundary of residual anstenite in the alloying zone. Pin-on-disc high-temperature wear tests were performed on samples both with and without the MMC coating at room temperature and at elevated temperatures （473 K and 623 K）, and the wear behavior and mechanism were investigated. The results showed that, after the PTA alloying treatment, the wear resistance of the sam- ples improved significantly. On the basis of our analysis of the composite coatings by optical microscopy, SEM with energy-dispersive X-ray spectroscopy, and microhardness measurements, we attributed this improvement of wear resistance to the transformation of the microstruc- ture and to the presence of TiC particles.