High-integrity diffusion bonding of laser powder bed fused, forged, and rolled Ti–6Al–4V alloys
Diffusion bonding of additively manufactured Ti–6Al–4V components with complex geometries to conventionally processed frames is a cost-effective approach for reducing the buy-to-fly ratio while minimizing deformation. This is the first study to investigate the diffusion bonding between laser powder...
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Elsevier
2025-03-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425001759 |
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| author | Seoyeon Jeon Hyunjong Ha Dong Jun Lee Hyeonil Park Yong Nam Kwon Hyunjoo Choi Hyokyung Sung |
| author_facet | Seoyeon Jeon Hyunjong Ha Dong Jun Lee Hyeonil Park Yong Nam Kwon Hyunjoo Choi Hyokyung Sung |
| author_sort | Seoyeon Jeon |
| collection | DOAJ |
| description | Diffusion bonding of additively manufactured Ti–6Al–4V components with complex geometries to conventionally processed frames is a cost-effective approach for reducing the buy-to-fly ratio while minimizing deformation. This is the first study to investigate the diffusion bonding between laser powder bed fusion (LPBF)-manufactured and conventionally processed Ti–6Al–4V alloys at various temperatures, durations, and pressures. Herein, the diffusion bonding of forged, rolled, and LPBF-manufactured Ti–6Al–4V alloys were examined under specific bonding conditions: 900 °C for bonding durations of 1 and 2 h and pressures of 2 and 4 MPa. Extended bonding durations led to β phase coarsening and thickened, elongated α′ laths in LPBFed materials, negatively impacting their mechanical properties. Optimal bonding was achieved at 900 °C for 2 h under 4 MPa, with bonding ratios exceeding 97%. Although LPBFed materials exhibited higher porosity than conventional alloys, which slightly reduced the bonding strength, microhardness and tensile testing revealed comparable bonding strengths. However, the LPBFed samples exhibited smaller elongation owing to the surface porosity. These findings suggest that diffusion bonding between LPBFed and conventional Ti–6Al–4V alloys can maintain mechanical integrity while reducing material waste, which presents a viable solution for aerospace component manufacturing. |
| format | Article |
| id | doaj-art-29fd2b5fe3174759825dddfa3b2e802c |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-29fd2b5fe3174759825dddfa3b2e802c2025-01-29T05:01:22ZengElsevierJournal of Materials Research and Technology2238-78542025-03-013521082118High-integrity diffusion bonding of laser powder bed fused, forged, and rolled Ti–6Al–4V alloysSeoyeon Jeon0Hyunjong Ha1Dong Jun Lee2Hyeonil Park3Yong Nam Kwon4Hyunjoo Choi5Hyokyung Sung6School of Materials Science and Engineering, Kookmin University, Seoul, 02707, South KoreaRebiality, Pyeongtaek, Gyeonggi, 17926, South KoreaMaterials Deformation Department, Korea Institute of Materials Science, Changwon, Gyeongnam, 51508, South KoreaMaterials Deformation Department, Korea Institute of Materials Science, Changwon, Gyeongnam, 51508, South KoreaMaterials Deformation Department, Korea Institute of Materials Science, Changwon, Gyeongnam, 51508, South Korea; Corresponding author.School of Materials Science and Engineering, Kookmin University, Seoul, 02707, South Korea; Corresponding author.School of Materials Science and Engineering, Kookmin University, Seoul, 02707, South Korea; Corresponding author.Diffusion bonding of additively manufactured Ti–6Al–4V components with complex geometries to conventionally processed frames is a cost-effective approach for reducing the buy-to-fly ratio while minimizing deformation. This is the first study to investigate the diffusion bonding between laser powder bed fusion (LPBF)-manufactured and conventionally processed Ti–6Al–4V alloys at various temperatures, durations, and pressures. Herein, the diffusion bonding of forged, rolled, and LPBF-manufactured Ti–6Al–4V alloys were examined under specific bonding conditions: 900 °C for bonding durations of 1 and 2 h and pressures of 2 and 4 MPa. Extended bonding durations led to β phase coarsening and thickened, elongated α′ laths in LPBFed materials, negatively impacting their mechanical properties. Optimal bonding was achieved at 900 °C for 2 h under 4 MPa, with bonding ratios exceeding 97%. Although LPBFed materials exhibited higher porosity than conventional alloys, which slightly reduced the bonding strength, microhardness and tensile testing revealed comparable bonding strengths. However, the LPBFed samples exhibited smaller elongation owing to the surface porosity. These findings suggest that diffusion bonding between LPBFed and conventional Ti–6Al–4V alloys can maintain mechanical integrity while reducing material waste, which presents a viable solution for aerospace component manufacturing.http://www.sciencedirect.com/science/article/pii/S2238785425001759Ti–6Al–4VDiffusion bondingLaser powder bed fusionMicrostructureMechanical properties |
| spellingShingle | Seoyeon Jeon Hyunjong Ha Dong Jun Lee Hyeonil Park Yong Nam Kwon Hyunjoo Choi Hyokyung Sung High-integrity diffusion bonding of laser powder bed fused, forged, and rolled Ti–6Al–4V alloys Journal of Materials Research and Technology Ti–6Al–4V Diffusion bonding Laser powder bed fusion Microstructure Mechanical properties |
| title | High-integrity diffusion bonding of laser powder bed fused, forged, and rolled Ti–6Al–4V alloys |
| title_full | High-integrity diffusion bonding of laser powder bed fused, forged, and rolled Ti–6Al–4V alloys |
| title_fullStr | High-integrity diffusion bonding of laser powder bed fused, forged, and rolled Ti–6Al–4V alloys |
| title_full_unstemmed | High-integrity diffusion bonding of laser powder bed fused, forged, and rolled Ti–6Al–4V alloys |
| title_short | High-integrity diffusion bonding of laser powder bed fused, forged, and rolled Ti–6Al–4V alloys |
| title_sort | high integrity diffusion bonding of laser powder bed fused forged and rolled ti 6al 4v alloys |
| topic | Ti–6Al–4V Diffusion bonding Laser powder bed fusion Microstructure Mechanical properties |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425001759 |
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