Additive Manufacturing of Ti-Based Intermetallic Alloys: A Review and Conceptualization of a Next-Generation Machine

TiAl-based intermetallic alloys have come to the fore as the preferred alloys for high-temperature applications. Conventional methods (casting, forging, sheet forming, extrusion, etc.) have been applied to produce TiAl intermetallic alloys. However, the inherent limitations of conventional methods do not permit the production of the TiAl alloys with intricate geometries. Additive manufacturing technologies such as electron beam melting (EBM) and laser powder bed fusion (LPBF), were used to produce TiAl alloys with complex geometries. EBM technology can produce crack-free TiAl components but lacks geometrical accuracy. LPBF technology has great geometrical precision that could be used to produce TiAl alloys with tailored complex geometries, but cannot produce crack-free TiAl components. To satisfy the current industrial requirement of producing crack-free TiAl alloys with tailored geometries, the paper proposes a new heating model for the LPBF manufacturing process. The model could maintain even temperature between the solidified and subsequent layers, reducing temperature gradients (residual stress), which could eliminate crack formation. The new conceptualized model also opens a window for in situ heat treatment of the built samples to obtain the desired TiAl (γ-phase) and Ti3Al (α2-phase) intermetallic phases for high-temperature operations. In situ heat treatment would also improve the homogeneity of the microstructure of LPBF manufactured samples.

Obtaining of Coatings from Ni-Al by Electro Spark Deposition and Surface Smoothing by Ultrasonic Plastic Deformation

The article presents the research results on obtaining coatings on steels 1030 and AISI 420 by the method of electrospark deposition and subsequent smoothing by means of ultrasonic surface plastic deformation (USPD). Intermetallic alloys consisting mainly of NiAl and Ni3Al phases were used as materials for obtaining coatings. It was found that the coatings consist of columnar crystallites of complex composition and have high plastic properties. To ensure the minimum parameters of the surface roughness of the obtained coatings, it is necessary to carry out 3-6 times of ultrasonic surface treatment.

Obtaining of Composite Alloys Based on Nickel Aluminides with Rare Metals

The paper presents the research results on the production of doped composite materials by the method of out-of-furnace liquid-phase self-propagating high-temperature synthesis using oxides and mineral concentrates containing Zr and W as a charge. The positive experience of producing ingots of intermetallic alloys based on the Ni-Al system in one stage of the reduction process of joint metallothermy is shown. The use of Zr in the charge leads to grinding of microstructure of the ingots and the formation of intermetallic compounds containing Zr. The additional use of C, B2O3, and W in the charge results in the formation of complex borides and tungsten carbides in the ingots. Additional introduction of Cr2O3 into the charge is necessary for the formation of W carbides in the nickel aluminide matrix.

Microstructure and Properties of TiAl-Based Alloys Melted in Graphite Crucible

This paper presents the chemical and phase composition, microstructure, and selected properties both at room temperature and at the temperature corresponding to the expected operating conditions of three successive generations of TiAl-based alloys (Ti-47Al-2W-0.5Si, Ti-45Al-8Nb-0.5(B,C), and Ti-45Al-5Nb-2Cr-1Mo-0.5(B,C)-0.2Si) melted in a vacuum induction furnace with high-density isostatic pressed graphite crucibles. The obtained results of mechanical and physical properties of the produced alloys were compared to the properties of reference alloys with similar chemical composition and melted in a cold copper crucible furnace. The effect of increased carbon content in the produced alloys due to the degradation of the graphite crucible during melting is higher strength properties, lower plastic properties, higher coefficient of thermal expansion, and improved creep resistance. It was shown that the proposed technology could be successfully used in the production of different generation TiAl-based intermetallic alloys.