The large strain extrusion-machining process has been used to refine the microstructure in a Titanium alloy (Ti–6Al–4V). The unconstrained cutting or machining of Ti–6Al–4V entails the formation of shear localized chips at nearly all cutting speeds, thereby hindering the use of extrusion-machining to produce fine-grained materials. The present effort attempts to suppress shear localization by the suitable modification of texture in Ti–6Al–4V through the cold-rolling process prior to extrusion-machining. Ti–6Al–4V plates were cold rolled to 30, 40, 45, and 47% thickness reductions. These textured plates were extrusion machined using a suitably designed fixture leading to fine-grained continuous foils with increased hardness. Microscopy has revealed that the suppression of shear localization in the foils produced from plates which are cold rolled to more than 40% of thickness reduction is triggered by texture formation. For thickness reductions slightly lower than 40% (e.g., 30%), suppression can be achieved only by a combination of texture and extrusion.
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The authors acknowledge Professors N.V. Ravi Kumar and V. Subramanya Sarma in the Department of Metallurgical and Materials Engineering at IIT Madras for their useful suggestions. Support rendered by the staff at the workshop in the Department of Engineering Design; the Physical Metallurgy Laboratory; and the Metal Forming Laboratory and Mechatronics Laboratory, IIT Madras are all gratefully acknowledged. The authors also acknowledge XRD facilities offered by the Department of Metallurgical and Materials Engineering at IIT Bombay to conduct bulk texture measurements. We are also thankful to the materials and manufacturing panel of the Aeronautics Research & Development Board (ARDB) for their support.
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Palaniappan, K., Murthy, H. & Rao, B.C. Production of fine-grained foils by large strain extrusion-machining of textured Ti–6Al–4V. Journal of Materials Research 33, 108–120 (2018). https://doi.org/10.1557/jmr.2017.445