Sustainable manufacturing of a high-value tubular Ti-6Al-4V component using flow-forming process; effect of feed-rate on microstructure evolution

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Banerjee, Amborish and Nelson, Kyle and Roszak, Jacob and Paslioglu, Kadir and Sivaswamy, Giribaskar and da Silva, Laurie and Rahimi, Salah (2025) Sustainable manufacturing of a high-value tubular Ti-6Al-4V component using flow-forming process; effect of feed-rate on microstructure evolution. Materials Chemistry and Physics, 344. 131086. ISSN 1879-3312 (https://doi.org/10.1016/j.matchemphys.2025.131086)

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Abstract

Flow-forming is a comparatively sustainable manufacturing process with a potential to produce seamless highvalue tubular components (e.g., actuators and shafts). This paper investigates microstructure evolution and the corresponding deformation mechanisms during warm (i.e., pre-heated to 600 ◦C) flow-forming of Ti–6Al–4V alloy under different feed rates. The increase in the feed-rate, from 1 to 2.5 mm/rev, which results in an increased roller-workpiece contact area, had led to longer final component (i.e., from 53 to 108 mm). EBSD analyses of microstructure suggest the occurrence of dynamic recrystallisation (DRX) in both α and β phases. Elongated α grains were observed in the outer surface, indicative of severe plastic deformation, accommodated by the deformation of the primary α grains and continuous dynamic recrystallisation (CDRX) in β. Analyses of crystallographic texture show the presence of strong B-fiber {1120} < 1100 > shear texture, indicating dominant shear deformation. The calculated Schmid factors for most of the α-grains were greater than 0.4 for the prismatic and pyramidal slip systems, thus indicating the dominant activation of these slip systems during flow-forming. These results elucidate the importance of rate-controlled thermal-mechanical interactions in tailoring the microstructure and manufacturability of titanium components via warm flow-forming.

ORCID iDs

Banerjee, Amborish ORCID logoORCID: https://orcid.org/0000-0003-4866-1337, Nelson, Kyle ORCID logoORCID: https://orcid.org/0009-0006-5617-2460, Roszak, Jacob ORCID logoORCID: https://orcid.org/0000-0003-4757-2391, Paslioglu, Kadir ORCID logoORCID: https://orcid.org/0000-0002-5090-1822, Sivaswamy, Giribaskar ORCID logoORCID: https://orcid.org/0000-0002-0603-9198, da Silva, Laurie ORCID logoORCID: https://orcid.org/0000-0002-3079-7909 and Rahimi, Salah ORCID logoORCID: https://orcid.org/0000-0001-6461-988X;
CORE (COnnecting REpositories)