Characterization and Optimization of Additive Manufacturing Process Parameters for Titanium Alloys

Thesis Abstract

Abstract
Additive manufacturing (AM) has emerged as a revolutionary technology in the field of materials and metallurgical engineering, offering unprecedented flexibility and design freedom in fabricating complex components. This thesis focuses on the characterization and optimization of AM process parameters for titanium alloys, which are widely used in aerospace, automotive, and medical industries due to their high strength-to-weight ratio and excellent corrosion resistance. The objective of this study is to investigate how different process parameters affect the microstructure, mechanical properties, and overall quality of additively manufactured titanium alloy components. The introduction provides an overview of the background of the study, highlighting the increasing demand for lightweight and high-performance materials in various industries. The problem statement emphasizes the need for a comprehensive understanding of the effects of process parameters on the final properties of additively manufactured titanium alloys. The objectives of the study include identifying the key process parameters, optimizing these parameters for enhanced performance, and characterizing the microstructure and mechanical properties of the fabricated components. The literature review chapter presents a detailed analysis of previous studies on AM of titanium alloys, focusing on the influence of process parameters such as laser power, scanning speed, and layer thickness on the final properties of the manufactured parts. The chapter also discusses the various techniques used for characterizing the microstructure and mechanical properties of titanium alloys, including microscopy, X-ray diffraction, and mechanical testing. The research methodology chapter outlines the experimental approach adopted in this study, including the selection of the titanium alloy material, the AM process parameters to be investigated, and the testing procedures for evaluating the microstructure and mechanical properties of the fabricated components. The chapter also describes the statistical methods used for data analysis and optimization of process parameters. The findings chapter presents a detailed analysis of the experimental results, including the effects of different process parameters on the microstructure, hardness, tensile strength, and fatigue properties of the additively manufactured titanium alloy components. The discussion highlights the relationships between process parameters and material properties, providing insights into the optimal parameter settings for achieving desired performance characteristics. In conclusion, this thesis contributes to the advancement of additive manufacturing technology by providing a comprehensive analysis of the effects of process parameters on the quality of titanium alloy components. The study demonstrates the importance of optimizing process parameters to enhance the mechanical properties and overall performance of additively manufactured parts. The findings of this research have significant implications for the aerospace, automotive, and medical industries, where lightweight and high-strength materials are essential for advanced engineering applications. Keywords Additive Manufacturing, Titanium Alloys, Process Parameters, Microstructure, Mechanical Properties, Optimization.