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Numerical Simulation, Microstructure, and Properties of TC4 Plasma Arc Additive Manufactured Thin Wall

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Abstract

Titanium alloys are widely used in aerospace and other fields due to their high strength, excellent wear resistance, corrosion resistance, biocompatibility and non-magnetic properties. This study validates the temperature evolution of 6-layer TC4 thin-walled parts through simulations and experiments. The simulations were reliable and accurate. The build process was performed by plasma arc additive manufacturing (PAAM) process. Further, the thermal elastic–plastic model and thermal stress field simulation of PAAM performed in reciprocating scanning sequence and unidirectional scanning sequence was carried out. Results showed alternating temperature gradients and uniform residual stress distribution in the reciprocating sequence. PAAM of TC4 thin walls in reciprocating scanning achieved excellent finish, accuracy, and no visible defects. The strength of the wall met ASTM forging standards. Microstructural analysis revealed reduced β phase and improved α phase through PAAM deposition. The lower region had Widmanstätten structure and basket-weave morphology, while the middle portion had relatively coarse basket-weave structure. The top region exhibited martensite structure and basket-weave structure. Tensile tests showed different strengths in scanning and build directions. Ultimate tensile strengths were 1013.7 and 965.1 MPa, with elongations of 6 and 7.9% respectively. Scanning direction had slightly higher strength but lower ductility.

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Data Availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

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Acknowledgments

This project is supported by Key Research and Development Project Zhejiang Province (2021C04022) and National Natural Science Foundation of China (Grant No. 52261135544), author Haoquan Zhang and Yujie Tao have equal contribution on the paper.

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  1. Haoquan Zhang and Yujie Tao haven been contributed equally to this work.

Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Wenzhou University, Wenzhou, 325035, People’s Republic of China

    Haoquan Zhang, Yujie Tao, Kang Peng & Xizhang Chen

  2. Pingyang Institute of Intelligent Manufacturing, Wenzhou University, Wenzhou, 325035, People’s Republic of China

    Kang Peng

  3. AKGEC Skills Foundation, Ajay Kumar Garg Engineering College, Ghaziabad, Uttar Pradesh, 201009, India

    N. Gangil

  4. Department of Mechanical Engineering, Ajay Kumar Garg Engineering College, Ghaziabad, Uttar Pradesh, 201009, India

    N. Gangil

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  1. Haoquan Zhang
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Haoquan Zhang contributed to conceptualization, investigation, methodology, writing–original draft. Yujie Tao contributed to supervision, writing—review and editing. Kang Peng and N. Gangil helped in supervision. Xizhang Chen helped in supervision and funding acquisition.

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Correspondence to Xizhang Chen.

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Zhang, H., Tao, Y., Peng, K. et al. Numerical Simulation, Microstructure, and Properties of TC4 Plasma Arc Additive Manufactured Thin Wall. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09507-2

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