Optimization of process parameters for TC11 alloy via tailoring scanning strategy in laser powder bed fusion

TC11, with a nominal composition of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si, is the preferred material for engine blisk due to its high-performance dual-phase titanium alloy, effectively enhancing engine aerodynamic efficiency and service reliability. However, in laser powder bed fusion (L-PBF) of TC11, challeng...

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Published inFrontiers of materials science Vol. 18; no. 4
Main Authors Shu, Chang, Zheng, Zhiyu, Lei, Peiran, Xu, Haijie, Shu, Xuedao, Essa, Khamis
Format Journal Article
LanguageEnglish
Published Beijing Higher Education Press 01.12.2024
Springer Nature B.V
Subjects
Beds (process engineering)
Blisks
Chemistry and Materials Science
Computational fluid dynamics
Design of experiments
Impact analysis
Lasers
Materials Science
Optimization
Powder beds
Process parameters
Reliability
Research Article
Tensile strength
Titanium alloys
Titanium base alloys
numerical modelling
TC11
mechanical property
parameter optimization
laser powder bed fusion
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Abstract TC11, with a nominal composition of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si, is the preferred material for engine blisk due to its high-performance dual-phase titanium alloy, effectively enhancing engine aerodynamic efficiency and service reliability. However, in laser powder bed fusion (L-PBF) of TC11, challenges such as inadequate defect control, inconsistent part quality, and limited optimization of key processing parameters hinder the process reliability and scalability. In this study, computational fluid dynamics (CFD) was used to simulate the L-PBF process, while design of experiments (DoE) was applied to analyze the effect of process parameters and determine the optimal process settings. Laser power was found to have the greatest impact on porosity. The optimal process parameters are 170 W laser power, 1100 mm·s −1 scanning speed, and 0.1 mm hatch spacing. Stripe, line, and chessboard scanning strategies were implemented using the optimal process parameters. The stripe scanning strategy has ∼33% (∼400 MPa) greater tensile strength over the line scanning strategy and ∼12% (∼170 MPa) over the chessboard scanning strategy. This research provides technical support for obtaining high-performance TC11 blisks.
AbstractList TC11, with a nominal composition of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si, is the preferred material for engine blisk due to its high-performance dual-phase titanium alloy, effectively enhancing engine aerodynamic efficiency and service reliability. However, in laser powder bed fusion (L-PBF) of TC11, challenges such as inadequate defect control, inconsistent part quality, and limited optimization of key processing parameters hinder the process reliability and scalability. In this study, computational fluid dynamics (CFD) was used to simulate the L-PBF process, while design of experiments (DoE) was applied to analyze the effect of process parameters and determine the optimal process settings. Laser power was found to have the greatest impact on porosity. The optimal process parameters are 170 W laser power, 1100 mm·s −1 scanning speed, and 0.1 mm hatch spacing. Stripe, line, and chessboard scanning strategies were implemented using the optimal process parameters. The stripe scanning strategy has ∼33% (∼400 MPa) greater tensile strength over the line scanning strategy and ∼12% (∼170 MPa) over the chessboard scanning strategy. This research provides technical support for obtaining high-performance TC11 blisks.
TC11, with a nominal composition of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si, is the preferred material for engine blisk due to its high-performance dual-phase titanium alloy, effectively enhancing engine aerodynamic efficiency and service reliability. However, in laser powder bed fusion (L-PBF) of TC11, challenges such as inadequate defect control, inconsistent part quality, and limited optimization of key processing parameters hinder the process reliability and scalability. In this study, computational fluid dynamics (CFD) was used to simulate the L-PBF process, while design of experiments (DoE) was applied to analyze the effect of process parameters and determine the optimal process settings. Laser power was found to have the greatest impact on porosity. The optimal process parameters are 170 W laser power, 1100 mm·s−1 scanning speed, and 0.1 mm hatch spacing. Stripe, line, and chessboard scanning strategies were implemented using the optimal process parameters. The stripe scanning strategy has ∼33% (∼400 MPa) greater tensile strength over the line scanning strategy and ∼12% (∼170 MPa) over the chessboard scanning strategy. This research provides technical support for obtaining high-performance TC11 blisks.
ArticleNumber 240710
Author Lei, Peiran
Xu, Haijie
Zheng, Zhiyu
Essa, Khamis
Shu, Chang
Shu, Xuedao
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  organization: Department of Mechanical Engineering, University of Birmingham
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mechanical property
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laser powder bed fusion
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  doi: 10.1016/j.powtec.2023.118610
– volume: 13
  start-page: 1366
  issue: 8
  year: 2022
  ident: 710_CR41
  publication-title: Micromachines
  doi: 10.3390/mi13081366
– volume: 776
  start-page: 138989
  year: 2020
  ident: 710_CR1
  publication-title: Materials Science and Engineering A
  doi: 10.1016/j.msea.2020.138989
SSID ssj0000515941
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Snippet TC11, with a nominal composition of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si, is the preferred material for engine blisk due to its high-performance dual-phase titanium...
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springer
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SubjectTerms Beds (process engineering)
Blisks
Chemistry and Materials Science
Computational fluid dynamics
Design of experiments
Impact analysis
Lasers
Materials Science
Optimization
Powder beds
Process parameters
Reliability
Research Article
Tensile strength
Titanium alloys
Titanium base alloys
Title Optimization of process parameters for TC11 alloy via tailoring scanning strategy in laser powder bed fusion
URI https://link.springer.com/article/10.1007/s11706-024-0710-z
https://www.proquest.com/docview/3142601255
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