Development of In-Process NDE Machining Force Feedback Analysis for Titanium Alloy Component Texture Analysis

钛合金被用于航空航天工业中的高性能旋转部件，特别是压缩机盘，因为它们具有高强度/重量比和优异的抗疲劳性和耐腐蚀性。钛合金产品通常经过锻造和机加工，近年来，机加工力反馈响应已被用于提供锻造材料中晶粒结构的指示以及上游锻造对织构发展的影响。该EngD项目的一个关键目标是开发力反馈方法，作为钛合金部件和上游锻造条件的非破坏性评估技术。一个方面是检测锻造材料中可能更倾向于在使用中限制性能特征的缺失的微纹理区域，并从这样的力反馈数据开发微结构数字孪生。该项目在先进材料的制造中非常重要，特别是考虑到为提高生产率而转向高速加工，因为没有可行的无损检测方法能够在加工材料时在线确定微观结构变化。这严重限制了新材料和加工技术的发展。如果能够开发出可靠的过程无损检测方法，这将不仅在锻造产品中，而且在其他需要减材加工的过程中（如增材制造）提供巨大的制造优势。开发工作还将通过关键的固态加工步骤提供工件材料的数字孪生的框架。

Titanium alloys are used in high performance rotating components in the aerospace industry, particularly compressor discs, as they possess high strength/weight ratios and excellent fatigue and corrosion re-sistance. Titanium alloy products are generally forged and machined, and over recent years, the ma-chining force feedback response has been used to provide an indication of grain structure in forged mate-rial and the influence of upstream forging on texture development. A key aim of this EngD project is to develop the force feedback approach as a non-destructive evaluation technique for titanium alloy components and upstream forged conditions. One aspect is to detect delete-rious micro-texture regions in forged material that may be more prone to performance limiting features in-service and develop a microstructural digital twin from such force feedback data. This project is hugely important in the manufacture of advanced materials, particularly considering the move to high speed machining for enhanced productivity, as there is no viable non-destructive inspec-tion method capable of determining microstructural variation on-line as the material is being machined. This severely limits the advancement of both new materials and machining techniques. If a reliable in-process NDE approach can be developed, this will provide a vast manufacturing advantage not just in forged product but in other processes that require subtractive machining, such as additive manufacturing. The development will work will also provide the framework of a digital twin of the workpiece material through key solid state processing steps.