Welding and cutting titanium
Seam protection
The weld must be as strong as the base material. Therefore, it is necessary to protect the weld pool area from contact with oxygen and nitrogen so that their content in the weld does not exceed 0.04-0.05 N2 and 0.15 O2. Hydrogen is the main source of pore formation during welding of titanium parts. It is actively released from the hot zone adjacent to the weld. In technical titanium with good weldability, hydrogen content should not exceed 0.01%, and in alloyed titanium alloys - 0.008%.
Sheet Welding
Hand argon-arc welding with non-fusing tungsten electrode with the filler wire is used for welding of titanium sheet with thickness of 1-15 mm and more. When welding a sheet 3-4 mm thick, edge cutting is not necessary, but a gap equal to half the sheet thickness is required. When welding sheet thickness of 4 - 10 mm requires V-shaped cut edges at an angle of 60 °. When welding sheets with thicknesses of more than 10 mm X-shaped edge cutting is required.
Cutting challenges
Titanium is difficult to cut due to its high strength. Therefore, cutting of titanium alloys requires considerable efforts, which, together with low thermal conductivity, leads to quick heating of the cut and requires cooling of the cutting area. Because of the strong adhesion, titanium builds up on the cutting edge, which further increases the friction force. In addition, the adhesion and welding of metal crumbs to the cutting edge results in changes in tool geometry. This entails higher machining forces, which consequently leads to an even higher temperature at the point of contact and accelerates tool wear. The increase in temperature in the working area is most affected by the cutting speed, and to a lesser extent by the tool feed force.
The Effects of High Temperatures
The temperature increase during cutting causes oxidation of the titanium chips and the workpiece. This subsequently poses a disposal and remelting problem for the chips. Titanium alloys containing chromium, manganese, vanadium, iron, molybdenum under the influence of high temperature change from β-phase to α-phase, which has increased brittleness. Therefore, heating can lead to a deterioration in the performance characteristics of the machined part.
Cutting optimization
The temperature in the cutting zone and the cutting force can be significantly reduced by increasing the hydrogen content in the alloy, vacuum annealing and appropriate machining. Conducting alloying of titanium alloys with hydrogen ultimately gives a significant reduction of temperature in the cutting zone, makes it possible to reduce the cutting force, increases the durability of the carbide tool up to 10 times, depending on the nature of the alloy and the mode of cutting. This method makes it possible to increase the processing speed by 2 times without loss of quality.
Combining operations
Technological processes that allow combining several operations into a single operation by using multi-tool equipment on multi-tool machines (machining centers) are widely used. For example, machines MA-655A, FP-17SMN, FP-27S are used for manufacturing of power parts from stampings, parts of "bracket", "column", "casing" types are used.column", "casing" of shaped castings and forgings - machines Horizont, Me-12-250, MA-655A, sheet panels - machine tool VFZ-M8. When machining most parts on these machines the principle of "maximum" completeness of machining in one operation is realized which is reached due to consecutive machining of a part from several sides on one machine by means of several fixtures installed on it.
Hydro-abrasive cutting
One of the main methods of cutting titanium is water-abrasive cutting with a high speed water jet under high pressure. Due to the optimization of production, it is possible to buy a water-jet cutting machine today at an optimal price. The advantages of this method are quite significant:
-reduces metal waste;
-Simplifies the production of complex parts;
-Reduces the cost of machining.
Cutting with a band saw
Cutting of titanium with a band saw is also possible, but in this case it is necessary to pay special attention to the speed and depth of cut. Maximum efficiency is achieved in case of high speed steel tools are used. In terms of machinability, titanium alloy can be compared with austenitic grade stainless steels.
Furnizor
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