Machinability and surface integrity analysis of Ti-17 alloy using WEDC for advanced aero-engine application
Recent advancements in aerospace industry demand intricate aero-engine parts, leading to the increased use of titanium alloys, particularly Ti-17, due to its high strength, thermal stability, and corrosion resistance. However, its low thermal conductivity and tool wear tendency pose significant mach...
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Elsevier
2025-01-01
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| Series: | Heliyon |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2405844024174920 |
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| author | Ramatenki Chinna Priyaranjan Sharma Filipe Fernandes |
| author_facet | Ramatenki Chinna Priyaranjan Sharma Filipe Fernandes |
| author_sort | Ramatenki Chinna |
| collection | DOAJ |
| description | Recent advancements in aerospace industry demand intricate aero-engine parts, leading to the increased use of titanium alloys, particularly Ti-17, due to its high strength, thermal stability, and corrosion resistance. However, its low thermal conductivity and tool wear tendency pose significant machining challenges, impacting surface integrity, fatigue life, and overall component performance. This study investigates the Wire Electrical Discharge Cutting (WEDC) process, revealing that the mechanism behind improved surface integrity lies in the controlled thermal input, which minimizes phase transformations and reduces residual stresses. Experimental results reveal that rough-cutting Ti-17 yields higher surface roughness of ∼2.68 μm than that of finish cutting of ∼1.01 μm, with increased microhardness up to 80 μm depth. Further, rough cutting leads to a thicker recast layer of ∼10–15 μm, and higher residual stresses of ∼540 MPa, while finish cutting achieves a thinner recast layer of ∼2–5 μm and reduced stresses of ∼304 MPa. The innovation of this study is the investigation of WEDC behavior in Ti-17 alloy, addressing a gap in understanding its surface integrity features to improve the performance, durability, and service life of aero-engine components, advancing next-generation aerospace manufacturing. |
| format | Article |
| id | doaj-art-ed06aa8f2ad045eda4cffaecf5f7713d |
| institution | Kabale University |
| issn | 2405-8440 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Heliyon |
| spelling | doaj-art-ed06aa8f2ad045eda4cffaecf5f7713d2025-01-17T04:51:21ZengElsevierHeliyon2405-84402025-01-01111e41461Machinability and surface integrity analysis of Ti-17 alloy using WEDC for advanced aero-engine applicationRamatenki Chinna0Priyaranjan Sharma1Filipe Fernandes2Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Guntur, 522302, AP, IndiaDepartment of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Guntur, 522302, AP, India; Corresponding author.University of Coimbra, CEMMPRE, ARISE, Department of Mechanical Engineering, Rua Luís Reis Santos, 3030-788, Coimbra, Portugal; CIDEM, ISEP - Polytechnic of Porto, Rua Dr. António Bernardino de Almeida, 4249-015, Porto, Portugal; Corresponding author. University of Coimbra, CEMMPRE, ARISE, Department of Mechanical Engineering, Rua Luís Reis Santos, 3030-788, Coimbra, Portugal.Recent advancements in aerospace industry demand intricate aero-engine parts, leading to the increased use of titanium alloys, particularly Ti-17, due to its high strength, thermal stability, and corrosion resistance. However, its low thermal conductivity and tool wear tendency pose significant machining challenges, impacting surface integrity, fatigue life, and overall component performance. This study investigates the Wire Electrical Discharge Cutting (WEDC) process, revealing that the mechanism behind improved surface integrity lies in the controlled thermal input, which minimizes phase transformations and reduces residual stresses. Experimental results reveal that rough-cutting Ti-17 yields higher surface roughness of ∼2.68 μm than that of finish cutting of ∼1.01 μm, with increased microhardness up to 80 μm depth. Further, rough cutting leads to a thicker recast layer of ∼10–15 μm, and higher residual stresses of ∼540 MPa, while finish cutting achieves a thinner recast layer of ∼2–5 μm and reduced stresses of ∼304 MPa. The innovation of this study is the investigation of WEDC behavior in Ti-17 alloy, addressing a gap in understanding its surface integrity features to improve the performance, durability, and service life of aero-engine components, advancing next-generation aerospace manufacturing.http://www.sciencedirect.com/science/article/pii/S2405844024174920Aero-engineSurface integrityRecast layerResidual stressesSurface roughnessFatigue life |
| spellingShingle | Ramatenki Chinna Priyaranjan Sharma Filipe Fernandes Machinability and surface integrity analysis of Ti-17 alloy using WEDC for advanced aero-engine application Heliyon Aero-engine Surface integrity Recast layer Residual stresses Surface roughness Fatigue life |
| title | Machinability and surface integrity analysis of Ti-17 alloy using WEDC for advanced aero-engine application |
| title_full | Machinability and surface integrity analysis of Ti-17 alloy using WEDC for advanced aero-engine application |
| title_fullStr | Machinability and surface integrity analysis of Ti-17 alloy using WEDC for advanced aero-engine application |
| title_full_unstemmed | Machinability and surface integrity analysis of Ti-17 alloy using WEDC for advanced aero-engine application |
| title_short | Machinability and surface integrity analysis of Ti-17 alloy using WEDC for advanced aero-engine application |
| title_sort | machinability and surface integrity analysis of ti 17 alloy using wedc for advanced aero engine application |
| topic | Aero-engine Surface integrity Recast layer Residual stresses Surface roughness Fatigue life |
| url | http://www.sciencedirect.com/science/article/pii/S2405844024174920 |
| work_keys_str_mv | AT ramatenkichinna machinabilityandsurfaceintegrityanalysisofti17alloyusingwedcforadvancedaeroengineapplication AT priyaranjansharma machinabilityandsurfaceintegrityanalysisofti17alloyusingwedcforadvancedaeroengineapplication AT filipefernandes machinabilityandsurfaceintegrityanalysisofti17alloyusingwedcforadvancedaeroengineapplication |