Improvement of Surface Mechanical and Tribological Characteristics of L-PBF Processed Commercially Pure Titanium through Ultrasonic Impact Treatment

doi:10.1007/s40195-024-01696-y

Abstract

Abstract:

Multi-pass ultrasonic impact treatment (UIT) was applied to modify the microstructure and improve the mechanical and tribological characteristics at the near-surface region of commercially pure Ti (CP-Ti) specimens produced by the laser powder bed fusion (L-PBF) method. UIT considerably refined the L-PBF process-related acicular martensites (α′-M) and produced a well-homogenized and dense surface microstructure, where the porosity content of 1-, 3-, and 5-pass UITed samples was reduced by 43, 60, and 67%, respectively. The UITed samples showed an enhancement in their near-surface mechanical properties up to a depth of about 300 μm. The nanoindentation results for the 3-pass UITed sample revealed an increase of about 53, 45, and 220% in its nanohardness, H/E_r, and H³/E_r² indices, respectively. The stylus profilometry results showed that performing the UIT removed the L-PBF-related features/defects and offered a smooth surface. The roughness average (R_a) and the skewness (R_sk) of the 3-pass UITed sample were found to be lower than those of the L-PBFed sample by 95 and 223%, respectively. Applying the UIT also enhanced the material ratio, where the maximum load-bearing capacity (~ 100%) in as-L-PBFed (as-built) and 3-pass UITed samples was obtained at 60- and 10-µm depths, respectively. The tribological investigations showed that applying the UIT resulted in a significant reduction of wear rate and average coefficient of friction (COF) of CP-Ti. For instance, under the normal pressures of 0.05 and 0.2 MPa, the wear rate and COF of the 3-pass UITed sample were lower than those of the L-PBFed sample by 65 and 58%, and 20 and 17%, respectively.

Key words: Laser powder bed fusion, Ultrasonic impact treatment, Commercially pure Ti (CP-Ti), Surface mechanical properties, Tribological properties

Iman Ansarian, Reza Taghiabadi, Saeid Amini, Mohammad Hossein Mosallanejad, Luca Iuliano, Abdollah Saboori. Improvement of Surface Mechanical and Tribological Characteristics of L-PBF Processed Commercially Pure Titanium through Ultrasonic Impact Treatment[J]. Acta Metallurgica Sinica (English Letters), 2024, 37(6): 1034-1046.

Figures/Tables 13

Fig. 1 Schematic diagram showing a the UIT setup and b the sample geometry along with the analyzed plane

Fig. 2 Optical microstructure of 3-pass UITed CP-Ti: a longitudinal section, b, c, and d transverse sections at the surface and depths of about 100 and 200 µm, respectively; e microhardness profile, f the effect of UIT pass number on the porosity content and the density of surface layer (~ 300-µm thickness) in CP-Ti samples

Fig. 3 XRD patterns of as-L-PBFed and 3-pass UITed samples. The locally-enlarged XRD patterns and the inset table show the peak broadening/shifting and crystal parameters, respectively

Table 1 Angle deviation and FWHM values for the selected peaks in Fig. 3

Sample	Peak position	Angle deviation	FWHM
As-L-PBFed	38.3592	0.0207	0.2668
	40.1229	0.0217	0.2360
	52.9438	0.0296	0.3313
	76.1607	0.0533	0.4466
3-pass UITed	38.3799	0.0207	0.4994
	40.1446	0.0217	0.7796
	52.9734	0.0296	0.5452
	76.2140	0.0533	1.1860

Fig. 4 Nanoindentation load-displacement curves of L-PBFed and 3-pass UITed samples

Table 2 Nanoindentation data obtained from load-displacement curves of the L-PBFed and 3-pass UITed samples

Sample	H (GPa)	E_r (GPa)	h_max (nm)	H/E_r	H³/E_r² (GPa)
As-L-PBFed	3.46	135.4	220.5	0.0255	0.0022
3-pass UITed	5.29	144.4	183.5	0.0366	0.0070

Fig. 5 Surface macro-morphologies of a as-L-PBFed and b 3-pass UITed samples; FESEM images showing the surface topography of c as-L-PBFed and d 3-pass UITed samples; roughness profiles of e as-L-PBFed and f 3-pass UITed samples; material ratio curves of g as-L-PBFed and h 3-pass UITed samples. The roughness parameters of as-L-PBFed and 3-pass UITed samples are presented at the inset of Fig. 5a and b, respectively

Fig. 6 Variation of a wear rate and b specific wear rate of as-L-PBFed and 3-pass UITed samples versus normal pressure

Fig. 7 FESEM images showing worn surfaces of the L-PBFed a-c and 3-pass UITed d and e samples. Applied normal pressures are shown on the micrographs. Figure 7c-I to 7c-III shows the EDS analyses of zones A, B, and C in Fig. 7c

Fig. 8 a FESEM image showing the wear debris morphology of the as-L-PBFed CP-Ti sample (normal pressure of 0.2 MPa), b EDS analysis corresponding to the point A in Fig. 8a, c-f secondary electron SEM image and the series of EDS elemental maps showing the distribution of Ti, Al, and O in a plate-like wear debris shown in Fig. 8c

Fig. 9 a FESEM image showing the wear debris morphology of the 3-pass UITed sample (normal pressure of 0.2 MPa), b EDS analysis corresponding to the point A in Fig. 9a, c-f secondary electron SEM image and the series of EDS elemental maps showing the distribution of Ti, Al, and O in a plate-like wear debris shown in Fig. 9c

Fig. 10 FESEM images related to the worn substrate microstructure of a L-PBFed CP-Ti and b 3-pass UITed CP-Ti samples under the normal pressure of 0.2 MPa

Fig. 11 COF curves of as-L-PBFed and 3-pass UITed samples under the normal pressures of a 0.05 MPa and b 0.2 MPa

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