Surface Defect Analysis and Process Improvement of Titanium Alloy Casting

SUN Yan; YE Dong; ZHANG Guang; YANG Dongli; QIE Xiwang; ZHAO Ruibin; NAN Hai

doi:10.3969/j.issn.1674-6457.2025.10.003

PDF(9377 KB)

Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (10) : 31-38. DOI: 10.3969/j.issn.1674-6457.2025.10.003

Light Alloy Forming

Surface Defect Analysis and Process Improvement of Titanium Alloy Casting

SUN Yan^1,*, YE Dong¹, ZHANG Guang¹, YANG Dongli¹, QIE Xiwang¹, ZHAO Ruibin¹, NAN Hai²

Author information +

History +

Abstract

Regarding the frequent surface defects, difficulty in repairing, and high scrap rate in a certain type of titanium alloy casting, the work aims to study the causes of surface defects and propose effective process improvement measures, so as to improve fluorescence performance and enhance surface quality of the casting. The type and causes of surface defects were determined by macroscopic observation, SEM microscopic morphology analysis, chemical composition analysis and hardness testing. Two improvement measures were developed based on incentives and experimental castings were produced to verify the improvement effect. The results indicated that surface defects of the titanium alloy casting were linear cracks, and exhibiting typical quasi-cleavage fracture characteristics. The residual hard and brittle α layer enriched with oxygen on the surface was the fundamental cause of the casting cracking. Two process improvement measures were taken: controlling parameters during the casting process and adding initial polishing to the radius structure with a thick α layer enriched with oxygen. After measures implemented, the first-time pass rate of fluorescence inspection of experimental castings significantly increased from 12.5% to 93.75%, with no scrap cases. This study solves frequent surface defects of the titanium alloy casting, improves the surface quality, shortens product lead time and is of great significance for reducing costs and increasing efficiency in actual production.

Key words

titanium alloy / investment casting / surface defects / fluorescent penetration testing / α layer enriched with oxygen

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

SUN Yan, YE Dong, ZHANG Guang, YANG Dongli, QIE Xiwang, ZHAO Ruibin, NAN Hai. Surface Defect Analysis and Process Improvement of Titanium Alloy Casting[J]. Journal of Netshape Forming Engineering. 2025, 17(10): 31-38 https://doi.org/10.3969/j.issn.1674-6457.2025.10.003

References

[1] 张美娟, 南海, 鞠忠强, 等. 航空铸造钛合金及其成型技术发展[J]. 航空材料学报, 2016, 36(3): 13-19.
ZHANG M J, NAN H, JU Z Q, et al.Aeronautical Cast Ti Alloy and Forming Technology Development[J]. Journal of Aeronautical Materials, 2016, 36(3): 13-19.
[2] MAMAYEVA A, PANICHKIN A, CHUKMANOVA M, et al.Investigation of the Mechanism for Interaction of Calcium Zirconate, Oxides of Calcium and Zirconium with Titanium Melts[J]. International Journal of Cast Metals Research, 2022, 35(5/6): 152-160.
[3] KONG Y F, LIU D, GUO X R, et al.Fluorescence Detection of Three Types of Pollutants Based on Fluorescence Resonance Energy Transfer and Its Comparison with Colorimetric Detection[J]. RSC Advances, 2023, 13(32): 22043-22053.
[4] MORADI B, ZOJAJI I, MOGHADAM A H, et al.Pore-scale Investigation of Wetting Strength on Capillary Pressure Hysteresis in a Realistic Porous Media[J]. Journal of Porous Media, 2022, 25(9): 51-69.
[5] 余慧澎, 康茂东, 王俊. 熔模精密铸件荧光自动检测技术研究进展及智能化发展趋势[J]. 铸造技术, 2023, 44(10): 953-963.
YU H P, KANG M D, WANG J.Research Progress and Intelligent Development Trend of Fluorescent Automatic Detection for Investment Castings[J]. Foundry Technology, 2023, 44(10): 953-963.
[6] 张传明, 张雷, 孙晓雪, 等. 钛合金铸件冶金缺陷线性荧光显示的动态定性法[J]. 铸造, 2023, 72(9): 1116-1121.
ZHANG C M, ZHANG L, SUN X X, et al.Dynamic Qualitative Method for Linear Fluorescent Display of Metallurgical Defects in Titanium Alloy Castings[J]. Foundry, 2023, 72(9): 1116-1121.
[7] VILLA R, LIU Y T, SIDDIQUE Z.Review of Defects and Their Sources in As-Built Ti₆Al₄V Manufactured via Powder Bed Fusion[J]. The International Journal of Advanced Manufacturing Technology, 2024, 132(9): 4105-4134.
[8] TRAN H T P, NGUYEN H S, BOUISSOU S. Experimental Analysis of the Extension to Shear Fracture Transition in a Rock Analogue Material Using Digital Image Correlation Method[J]. International Journal of Fracture, 2023, 243(1): 91-104.
[9] OKADA K, SHIBATA A, MATSUMIYA H, et al.Origin of Serrated Markings on the Hydrogen Related Quasi-Cleavage Fracturein Low-Carbon Steel with Ferrite Microstructure[J]. ISIJ International, 2022, 62(10): 2081-2088.
[10] 谷臣泉. 金属材料化学成分检测潜在问题及其对策研究[J]. 冶金与材料, 2024, 16(1): 70-72.
GU C Q.Study on Potential Problems and Countermeasures of Chemical Composition Detection of Metal Materials[J]. Metallurgy and Materials, 2024, 16(1): 70-72.
[11] 何景瓷. 金属材料物理性能检测技术分析[J]. 造纸装备及材料, 2022, 51(3): 91-93.
HE J C.Analysis of Physical Properties Testing Technology of Metal Materials[J]. Papermaking Equipment & Materials, 2022, 51(3): 91-93.
[12] FEI H, PAN B J, ZHANG C, et al.Study on the Mechanical Properties Gradient in Surface Oxygen Diffusion Hardened Layer of Ti₆Al₄V Alloy[J]. Journal of Materials Research and Technology, 2022, 18: 3173-3183.
[13] 杜陕文, 张延生. 钛及钛合金表面脆性α层的重腐蚀法测定[J]. 稀有金属, 2004, 28(1): 277-280.
DU S W, ZHANG Y S.Determination of Brittle α Case on Surface of Titanium and Titanium Alloy by Re-etching Method[J]. Chinese Journal of Rare Metals, 2004, 28(1): 277-280.
[14] 闫文萱, 邵洙浩, 李伟, 等. 3种钛合金富氧α层的生长规律[J]. 金属热处理, 2023, 48(11): 68-72.
YAN W X, SHAO Z H, LI W, et al.Growth Law of Oxygen-Rich α Layer of Three Titanium Alloys[J]. Heat Treatment of Metals, 2023, 48(11): 68-72.
[15] 高守林, 黄重国, 雷鹍, 等. 热处理对TC4钛合金富氧α层的影响[J]. 热加工工艺, 2018, 47(20): 243-246.
GAO S L, HUANG Z G, LEI K, et al.Effects of Heat Treatment on Oxygen-Rich α-Layer of TC4 Titanium Alloy[J]. Hot Working Technology, 2018, 47(20): 243-246.
[16] 孙宗帅, 齐会萍, 宋鑫, 等. Ti-6Al-4V合金温变形性能研究[J]. 精密成形工程, 2024, 16(9): 153-160.
SUN Z S, QI H P, SONG X, et al.Warm Deformation Properties of Ti-6Al-4V Alloys[J]. Journal of Netshape Forming Engineering, 2024, 16(9): 153-160.
[17] 项征. 大型复杂钛合金薄壁件精铸成型技术[J]. 轻合金加工技术, 2024, 52(1): 1-6.
XIANG Z.Precision Casting Technology for Large and Complex Titanium Alloy Thin-Walled Parts[J]. Light Alloy Fabrication Technology, 2024, 52(1): 1-6.
[18] ZHOU S, AN J L, WANG X M, et al.Study on Fatigue Crack Propagation Behavior of TA15 Titanium Alloy Repaired by Laser Deposition Repair[J]. Fatigue & Fracture of Engineering Materials & Structures, 2022, 45(12): 3692-3700.
[19] 匡格平, 王群, 黄学伟, 等. TA17钛合金板状连接件的疲劳裂纹扩展行为研究[J]. 宇航材料工艺, 2024, 54(2): 75-81.
KUANG G P, WANG Q, HUANG X W, et al.Investigation on Fatigue Crack Growth Behavior of TA17 Ti Alloy Connection[J]. Aerospace Materials & Technology, 2024, 54(2): 75-81.
[20] 周牧, 王倩, 王延绪, 等. 焊前预处理对钛合金厚板焊接残余应力的影响[J]. 金属学报, 2024, 60(8): 1064-1078.
ZHOU M, WANG Q, WANG Y X, et al.Effect of Prewelding Pretreatment on Welding Residual Stress of Titanium Alloy Thick Plate[J]. Acta Metallurgica Sinica, 2024, 60(8): 1064-1078.
[21] HUANG L, KINNELL P, SHIPWAY P H.Removal of Heat-Formed Coating from a Titanium Alloy Using High Pressure Waterjet: Influence of Machining Parameters on Surface Texture and Residual Stress[J]. Journal of Materials Processing Technology, 2015, 223: 129-138.
[22] 陈果, 曾大新, 周家林. 镁合金铸型界面反应及阻止反应技术[J]. 热加工工艺, 2012, 41(15): 47-49.
CHEN G, ZENG D X, ZHOU J L.Reactions and Their Inhibition Techniques on Magnesium Mould Interface[J]. Hot Working Technology, 2012, 41(15): 47-49.
[23] LIU J, LIU C.Optimization of Mold Inverse Oscillation Control Parameters in Continuous Casting Process[J]. Materials and Manufacturing Processes, 2015, 30(4): 563-568.
[24] 乔永莲, 刘会军, 许茜, 等. TC4钛合金表面氧化皮去除[J]. 沈阳工业大学学报, 2014, 36(2): 165-169.
QIAO Y L, LIU H J, XU Q, et al.Removal of Oxide Skin on Surface of TC4 Titanium Alloy[J]. Journal of Shenyang University of Technology, 2014, 36(2): 165-169.
[25] 王帅. 基于工业机器人的铸件打磨关键技术研究[D]. 石家庄: 石家庄铁道大学, 2024: 8-10.
WANG S.Research on Key Technology of Casting Grinding Based on Industrial Robot[D]. Shijiazhuang: Shijiazhuang Tiedao University, 2024: 8-10.
[26] CHEN H X, ZHANG G X, LIU N, et al.Surface Quality of SLM TC4 Titanium Alloy Surface by MAF[J]. China Surface Engineering, 2023, 36(1): 106-115.