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<p>The casting of Ti6Al4V alloy can often result in suboptimal mechanical properties due to the presence of porosity and shrinkage. Industrial computed tomography (CT) was employed to assess the distribution, size, and morphology of pores within the investment casting of complex aero-engine blades produced in this alloy. Finite element simulations were conducted based on the identified pore characteristics, leading to the development of response surface models. An optimal hot isostatic pressing (HIP) regime was designed to eliminate the pores, alter the microstructure, and enhance the mechanical properties of the material. The results demonstrated that the toughness of the cast Ti6Al4V alloy increased by nearly 100% following HIP treatment, while its tensile strength remained relatively unchanged. Characterization of the material before and after HIP using optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) revealed complete pore closure without significant alterations in elemental distribution under the conditions of 950&#xa0;°C, 120 MPa for 60 minutes utilized in this study, which is advantageous for a substantial increase in elongation. Post-HIP treatment did not induce excessive grain growth; rather, it led to an increase in the number of small grains and the emergence of needle-like variants. A reduction in geometrically necessary dislocation density contributed to the enhancement of tensile strength. The microstructural changes induced by HIP treatment had minimal impact on overall material performance and negated the need for additional heat treatment for microstructural adjustment. The process developed in this study significantly improved the mechanical properties of the material while achieving over 60% energy savings compared to conventional HIP processes. The omission of heat treatment resulted in an overall post-treatment efficiency increase exceeding 300%.</p>

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Design and Experimental Validation of Rapid Hot Isostatic Pressing Process for Ti6Al4V Alloy

  • 期刊论文

  • 发表日期：

    2025年1月8日

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  • Lantian Guo,
  • Weifang Mann,
  • Kangjie Chen,
  • Bo He

摘要

The casting of Ti6Al4V alloy can often result in suboptimal mechanical properties due to the presence of porosity and shrinkage. Industrial computed tomography (CT) was employed to assess the distribution, size, and morphology of pores within the investment casting of complex aero-engine blades produced in this alloy. Finite element simulations were conducted based on the identified pore characteristics, leading to the development of response surface models. An optimal hot isostatic pressing (HIP) regime was designed to eliminate the pores, alter the microstructure, and enhance the mechanical properties of the material. The results demonstrated that the toughness of the cast Ti6Al4V alloy increased by nearly 100% following HIP treatment, while its tensile strength remained relatively unchanged. Characterization of the material before and after HIP using optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) revealed complete pore closure without significant alterations in elemental distribution under the conditions of 950 °C, 120 MPa for 60 minutes utilized in this study, which is advantageous for a substantial increase in elongation. Post-HIP treatment did not induce excessive grain growth; rather, it led to an increase in the number of small grains and the emergence of needle-like variants. A reduction in geometrically necessary dislocation density contributed to the enhancement of tensile strength. The microstructural changes induced by HIP treatment had minimal impact on overall material performance and negated the need for additional heat treatment for microstructural adjustment. The process developed in this study significantly improved the mechanical properties of the material while achieving over 60% energy savings compared to conventional HIP processes. The omission of heat treatment resulted in an overall post-treatment efficiency increase exceeding 300%.