The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting

Additive manufacturing (AM) is a powder bed process for the build-up of parts by the distribution of material in which laser power melts the powder layer by layer as generated from a three-dimensional (3D) model design. Selective laser melting (SLM) is an AM method that enables the manufacture of co...

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Main Author:	Sadali, Mohd. Faizal
Format:	Thesis
Language:	English
Published:	2022
Subjects:	Q Science (General) T Technology (General)
Online Access:	http://eprints.utm.my/id/eprint/102393/1/MohdFaizalSadaliPRAZAK2022.pdf
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id	my-utm-ep.102393
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spelling	my-utm-ep.1023932023-08-28T06:24:42Z The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting 2022 Sadali, Mohd. Faizal Q Science (General) T Technology (General) Additive manufacturing (AM) is a powder bed process for the build-up of parts by the distribution of material in which laser power melts the powder layer by layer as generated from a three-dimensional (3D) model design. Selective laser melting (SLM) is an AM method that enables the manufacture of complex geometries, lighter and stronger parts. In this research, the SLM parameters like scanning speed, laser power, and hatching distance were studied using Ti6Al4V powder. The influence of parameters on the surface morphology, surface roughness, and hardness of Ti6Al4V parts was characterised using field emission scanning electron microscope (FESEM), hardness tests, and 3D profiler analysis. In addition, the surface morphology was studied to prove its significance in terms of micropores, balling, and splashing effects. Results showed that the quality of produced parts from SLM was significantly affected by various manufacturing parameters. Hence, the orthogonal array design of experiment was conducted, and statistical analysis with signal-to-noise response was used to obtain the optimal SLM parameters. The experimental outcomes showed that laser power had a high impact on density. Besides, a confirmation experiment was carried out by using optimal parameters (P = 175W, v = 852.5mm/s, and h = 0.13mm) and it was proven that the density increased to 99.933%. The optimal parameter was then implemented to produce body cubic centric (BCC), body cubic centric in Z direction (BCCZ), body cubic centric Z direction in centre (BCCZC), face cubic centric (FCC), and face body cubic centric (FBCC) Ti6Al4V lattice structures. The mathematical modelling, finite element analysis, and experimental studies were conducted to predict and compare the quality of the SLM product. It was discovered that the BCCZ had the highest strength at 5000 MPa. Moreover, the strut and fractured struts were examined to carry out the microcrack and void effect on the strut. The Ashby graph was deployed and the lattice structure was in the range of Ti6 strength. Based on this, the optimal SLM parameters were observed to produce a Ti6Al4V part which had the potential for aerospace, automotive, and biomedical industries. It can be highlighted that this study approached the national policy on Industrial Revolution 4.0 (4IR) through future technologies. 2022 Thesis http://eprints.utm.my/id/eprint/102393/ http://eprints.utm.my/id/eprint/102393/1/MohdFaizalSadaliPRAZAK2022.pdf application/pdf en public http://dms.library.utm.my:8080/vital/access/manager/Repository/vital:151663 phd doctoral Universiti Teknologi Malaysia, Razak Faculty of Technology & Informatics Razak Faculty of Technology & Informatics
institution	Universiti Teknologi Malaysia
collection	UTM Institutional Repository
language	English
topic	Q Science (General) T Technology (General)
spellingShingle	Q Science (General) T Technology (General) Sadali, Mohd. Faizal The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting
description	Additive manufacturing (AM) is a powder bed process for the build-up of parts by the distribution of material in which laser power melts the powder layer by layer as generated from a three-dimensional (3D) model design. Selective laser melting (SLM) is an AM method that enables the manufacture of complex geometries, lighter and stronger parts. In this research, the SLM parameters like scanning speed, laser power, and hatching distance were studied using Ti6Al4V powder. The influence of parameters on the surface morphology, surface roughness, and hardness of Ti6Al4V parts was characterised using field emission scanning electron microscope (FESEM), hardness tests, and 3D profiler analysis. In addition, the surface morphology was studied to prove its significance in terms of micropores, balling, and splashing effects. Results showed that the quality of produced parts from SLM was significantly affected by various manufacturing parameters. Hence, the orthogonal array design of experiment was conducted, and statistical analysis with signal-to-noise response was used to obtain the optimal SLM parameters. The experimental outcomes showed that laser power had a high impact on density. Besides, a confirmation experiment was carried out by using optimal parameters (P = 175W, v = 852.5mm/s, and h = 0.13mm) and it was proven that the density increased to 99.933%. The optimal parameter was then implemented to produce body cubic centric (BCC), body cubic centric in Z direction (BCCZ), body cubic centric Z direction in centre (BCCZC), face cubic centric (FCC), and face body cubic centric (FBCC) Ti6Al4V lattice structures. The mathematical modelling, finite element analysis, and experimental studies were conducted to predict and compare the quality of the SLM product. It was discovered that the BCCZ had the highest strength at 5000 MPa. Moreover, the strut and fractured struts were examined to carry out the microcrack and void effect on the strut. The Ashby graph was deployed and the lattice structure was in the range of Ti6 strength. Based on this, the optimal SLM parameters were observed to produce a Ti6Al4V part which had the potential for aerospace, automotive, and biomedical industries. It can be highlighted that this study approached the national policy on Industrial Revolution 4.0 (4IR) through future technologies.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Sadali, Mohd. Faizal
author_facet	Sadali, Mohd. Faizal
author_sort	Sadali, Mohd. Faizal
title	The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting
title_short	The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting
title_full	The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting
title_fullStr	The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting
title_full_unstemmed	The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting
title_sort	enhancement of process parameters to improve microstructures and mechanical properties of ti-6al-4v alloy produced by selective laser melting
granting_institution	Universiti Teknologi Malaysia, Razak Faculty of Technology & Informatics
granting_department	Razak Faculty of Technology & Informatics
publishDate	2022
url	http://eprints.utm.my/id/eprint/102393/1/MohdFaizalSadaliPRAZAK2022.pdf
_version_	1776100912508436480

The enhancement of process parameters to improve microstructures and mechanical properties of TI-6AL-4V alloy produced by selective laser melting

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