The titanium alloy components utilized in the aviation field are typically large in size and possess complex structures. By utilizing multiple additive manufacturing processes, the precision and efficiency requirements of production can be met. We investigated the hybrid additive manufacturing of Ti-6Al-4V using a combination of cold metal transfer additive manufacturing (CMTAM) and laser metal deposition (LMD), as well as the feasibility of using the CMT-LMD hybrid additive manufacturing process for fabricating Ti-6Al-4V components. Microstructural examinations, tensile testing coupled with digital image correlation and dynamic compressive experiments (by the split Hopkinson pressure bar (SHPB) system) were employed to assess the parts. The results indicate that the interface of the LMD and CMTAM zone formed a compact metallurgical bonding. In the CMTAM and LMD zone, the prior-β grains exhibit epitaxial growth, forming columnar prior-β grains. Due to laser remelting, the CMT-LMD hybrid additive zone experiences grain refinement, resulting in equiaxed prior-β grains at the interface with an average grain size smaller than that of the CMTAM and LMD regions. The microstructures reveal significant differences in grain orientation and morphology among the zones, with distinct textures forming in each zone. In the CMT-LMD hybrid zone, due to interfacial strengthening, strain concentration occurs in the arc additive zone during tensile testing, leading to fracture on the CMTAM zone. Under high-strain-rate dynamic impact conditions, the LMD region exhibits ductile fracture, while the CMTAM zone demonstrates brittle fracture. The hybrid zone combines ductile and brittle fracture modes, and the CMT-LMD hybrid material exhibits superior dynamic impact performance compared to the single deposition zone.

Selective laser melting (SLM) can effectively replace traditional processing methods to prepare parts with arbitrary complex shapes through layer-by-layer accumulation. However, SLM Ti-6Al-4V alloy typically exhibits low ductility and significant mechanical properties anisotropy due to the presence of acicular α\' martensite and columnar prior β grains. Post-heat treatment is frequently used to obtain superior mechanical properties by decomposing acicular α\' martensite into an equilibrium α + β phase. In this study, the microstructure and tensile properties of SLM Ti-6Al-4V alloy before and after various heat treatments were systematically investigated. The microstructure of the as-fabricated Ti-6Al-4V sample was composed of columnar prior β grains and acicular α\' martensite, which led to high strength (~1400 MPa) but low ductility (~5%) as well as significantly tensile anisotropy. The single heat treatment samples with lamellar α + β microstructure exhibited improved elongation to 6.8-13.1% with a sacrifice of strength of 100-200 MPa, while the tensile anisotropy was weakened. A trimodal microstructure was achieved through multi-step high-to-low-temperature (HLT) heat treatment, resulting in an excellent combination of strength (~1090 MPa) and ductility (~17%), while the tensile anisotropy was almost eliminated. The comprehensive mechanical properties of the HLT samples were superior to that of the conventional manufactured Ti-6Al-4V alloy.

The finite element (FE) method is used to characterize the thermal gradient, solidification rate, and molten pool sizes of Ti-6Al-4V plates in the process of selective laser melting (SLM). The results are verified by using the computational fluid dynamics (CFD) simulation. The proposed FE model contains a series of toolpath information that is directly converted from a G-code file, including hatch spacing, laser power, layer thickness, dwell time, and scanning speed generated by using Slic3r software from a CAD file. A proposed multi-layer, multi-track FE model is used to investigate the influence of the laser power, scanning speed, and scanning path on the microstructure in the Ti-6Al-4V plate built via SLM. The processing window is also determined based on the proposed FE model. The FE results indicate that, with a decrease in the laser power and an increase in the scanning speed, the morphology of the crystal grains, showing fully columnar crystals, gradually deviates from the fully equiaxed region. The formed grains are dependent on the laser power, scanning speed, and deposition position, but they are not sensitive to the scanning path, and with the deposition from the bottom layer to the top layer, the size of the formed grains is gradually increasing, which shows a good agreement with the experimental results.

TiAlN-coated carbide tools have been used to machine Ti-6Al-4V alloys in aviation workshops. However, the effect of TiAlN coating on surface morphology and tool wear in the processing of Ti-6Al-4V alloys under various cooling conditions has not been reported in the public published literature. In our current research, turning experiments of Ti-6Al-4V with uncoated and TiAlN tools under dry, MQL, flood cooling, and cryogenic spray jet cooling conditions were carried out. The machined surface roughness and tool life were selected as the two main quantitative indexes for estimating the effects of TiAlN coating on the cutting performance of Ti-6Al-4V under various cooling conditions. The results showed that TiAlN coating makes it hard to improve the machined surface roughness and tool wear of a cutting titanium alloy at a low speed of 75 m/min compared to that achieved by uncoated tools. The TiAlN tools presented excellent tool life in turning Ti-6Al-4V at a high speed of 150 m/min compared to that achieved by uncoated tools. From the perspective of obtaining finished surface roughness and superior tool life in high-speed turning Ti-6Al-4V, the selection of TiAlN tools is feasible and reasonable under the cryogenic spray jet cooling condition. The dedicative results and conclusions of this research could guide the optimized selection of cutting tools in machining Ti-6Al-4V for the aviation industry.

To investigate the mechanical property and failure behavior of laser metal deposited additive manufacturing Ti-6Al-4V (LMD Ti64) in a wide range of stress states and strain rates, different types of specimens were tested at strain rates of 0.001-5000/s. Numerical simulations were conducted to collect the local fracture strain at the critical position where the failure happened for all specimens. By comparing with Ti64 alloy manufactured by different techniques, the failure behavior of LMD Ti64 alloy shows a stronger sensitivity to Lode angle parameter and strain rate. The role of initial defects in failure was discussed. It is found that high laser power and overlap ratio can improve the failure behavior by reducing the number of initial defects. The initial defects on the fracture surface at much higher strain rates were observed, indicating that the initial crack rather than initial void acts as the crack growth point leading to the final fracture at higher strain rates. The scanning electron microscope observation of the fracture surface shows that the failure mechanism of LMD Ti64 alloy varies from different stress states and strain rates. The failure mechanism is characterized by the shear fracture at the negative stress triaxiality, whereas the void growth fracture plays a dominant role in the failure mechanism of LMD Ti64 alloy at a high stress triaxiality on the quasi-static loading condition.

In this paper, five grading functional gradient lattice structures with a different density perpendicular to the loading direction were proposed, and the surface morphology, deformation behavior, and compression properties of the functional gradient lattice structures prepared by selective laser melting (SLM) with Ti-6Al-4V as the building material were investigated. The results show that the characteristics of the laser energy distribution of the SLM molding process make the spherical metal powder adhere to the surface of the lattice structure struts, resulting in the actual relative density of the lattice structure being higher than the designed theoretical relative density, but the maximum error does not exceed 3.33%. With the same relative density, all lattice structures with density gradients perpendicular to the loading direction have better mechanical properties than the uniform lattice structure, in particular, the elastic modulus of LF, the yield strength of LINEAR, and the first maximum compression strength of INDEX are 28.99%, 16.77%, and 14.46% higher than that of the UNIFORM. In addition, the energy absorption per unit volume of the INDEX and LINEAR is 38.38% and 48.29% higher, respectively, than that of the UNIFORM. Fracture morphology analysis shows that the fracture morphology of these lattice structures shows dimples and smooth planes, indicating that the lattice structure exhibits a mixed brittle and ductile failure mechanism under compressive loading. Finite element analysis results show that when the loading direction is perpendicular to the density gradient-forming direction, the higher density part of the lattice structure is the main bearing part, and the greater the density difference between the two ends of the lattice structure, the greater the elastic modulus.

At solid-liquid interfaces, charged particles within the electric double layer (EDL) are acted on by the electrostatic force, which may affect cell absorption and surface wettability. In this study, a model of the electrostatic force and surface tension of textured surfaces was presented. Then, the growth and adhesion of Murine osteoblasts (MC3T3-E1) cells on laser-ablated micro-square-textured Ti-6Al-4V surfaces were studied to demonstrate the use of a laser-processed texture to effectively improve bioactivity. Three different micro-square-textured hydrophilic surfaces, presenting lower contact angles of 19°, 22.5°, and 31.75° compared with that of a smooth surface (56.5°), were fabricated using a fiber-optic laser. Cellular morphology and initial cell attachment were analyzed by field emission scanning electron microscopy (SEM) and fluorescence microscopy, respectively. The results show that the electrostatic force not only made the textured surface more hydrophilic but also made the cells tend to adhere to the edges and corners of the protruding convexes. Cell morphology analysis also showed that cells would prefer to grow at the edges and corners of each micro-square convex protrusion. The laser-treated surfaces were more conducive to rapid cell growth and adhesion, and cells were preferentially attached on the hydrophilic-textured surfaces. Electrostatic force may be an important factor in effectively improving the bioactivity of Ti-6Al-4V surfaces, and the presence of more surface grooves would be more conducive to improving the bioactivity of cells.

Titanium alloy materials are used in a variety of engineering applications in the aerospace, aircraft, electronics, and shipbuilding industries, and due to the continuous improvement of the contemporary age, surface integrity needs to be improved for engineering applications. Belt grinding parameters and levels directly affect the surface integrity of titanium alloys (TC4), which further affects the fatigue life of the titanium alloys during service. In order to investigate the surface integrity of titanium alloys at different roughness levels, the surfaces were repeatedly ground with the same type and different models of abrasive belts. The results showed that at roughness Ra levels of 0.4 μm to 0.2 μm, the compressive residual stresses decreased with increasing linear velocity and there were problems with large surface morphological defects. At the roughness Ra of 0.2 μm or less, grinding improves the surface morphology, the compressive residual stress increases with increasing feed rate, and the surface hardness decreases with increasing linear velocity. In addition, the research facilitates the engineering of grinding parameters and levels that affect surface integrity under different roughness conditions, providing a theoretical basis and practical reference.

In this paper, a milling force prediction model considering the Taylor factor is established, and the Ti-6Al-4V milling force predicted by the model under different milling parameters is presented. In the study, the milling experiment of Ti-6Al-4V was carried out, the milling force was collected by the dynamometer, and the microstructure evolution of the milling surface before and after milling was observed by EBSD. Through the comparative analysis of the experimental results and the model prediction results, the reliability of the prediction model proposed in this study was verified, and the influences of the milling parameters on the milling force were further analyzed. Finally, based on the EBSD observation results, the effects of the milling parameters on the microstructure evolution of the milling surface were studied. The results show that both the tangential milling force and normal milling force increase with the increase in the milling depth and feed rate. Among the milling parameters selected in this study, the milling depth has the greatest influence on the milling force. The average errors of the tangential milling force and normal milling force predicted by the milling force model are less than 10%, indicating that the milling force prediction model established in this paper considering Taylor factor is suitable for the prediction of the Ti-6Al-4V milling force. With the change in the milling parameters, the grain structure, grain size, grain boundary distribution, phase distribution, and micro-texture of the material surface change to varying degrees, and the plastic deformation of the milling surface is largely coordinated by the slip.

Determining the quality of Ti-6Al-4V parts fabricated by selective laser melting (SLM) remains a challenge due to the high cost of SLM and the need for expertise in processes and materials. In order to understand the correspondence of the relative density of SLMed Ti-6Al-4V parts with process parameters, an optimized extreme gradient boosting (XGBoost) decision tree model was developed in the present paper using hyperparameter optimization with the GridsearchCV method. In particular, the effect of the size of the dataset for model training and testing on model prediction accuracy was examined. The results show that with the reduction in dataset size, the prediction accuracy of the proposed model decreases, but the overall accuracy can be maintained within a relatively high accuracy range, showing good agreement with the experimental results. Based on a small dataset, the prediction accuracy of the optimized XGBoost model was also compared with that of artificial neural network (ANN) and support vector regression (SVR) models, and it was found that the optimized XGBoost model has better evaluation indicators such as mean absolute error, root mean square error, and the coefficient of determination. In addition, the optimized XGBoost model can be easily extended to the prediction of mechanical properties of more metal materials manufactured by SLM processes.