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Oxidation of Ti-6Al-4V During Wire and Arc Additive Manufacture
Oxidation of Ti-6Al-4V During Wire and Arc Additive Manufacture
Abstract
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Owing to the high reactivity of titanium with oxygen at high temperatures, oxidation is often observed during
wire and arc additive manufacture (WAAM) of Ti-6Al-4V. As a sign of oxidation, discoloration of titanium
components built by WAAM is usually observed, due to the formation of a thin oxide scale on the surface. This
generally constitutes a major concern from the end user. Together with the oxide scale, oxidation also produces
the formation of a brittle oxygen-enriched layer near the surface (Alpha Case) and it can be detrimental in terms
of mechanical properties. Hence, it is of major interest to investigate the influence of surface oxidation on the
bulk material property of WAAM of Ti-6Al-4V and understand the oxidation process during WAAM depo-
sition. In this work, oxidation of titanium during WAAM was investigated to determine the mechanisms and
main process parameters controlling this phenomenon. To address this, plasma-transferred arc and wire de-
position samples were manufactured by changing either deposition parameters or oxygen levels in the fu-
sion atmosphere. Subsequently, samples were characterized by means of visual inspection, optical microscope,
scanning electron microscope, and tensile mechanical testing. For any containing level of oxygen in the
shielding environment, it was found that if temperatures are high enough and exposure times long, oxidation of
titanium is observed. In addition, it was possible to determine that oxidation is more significant in the region of
the first deposited layers. The maximum depth of Alpha Case was found to be 200 lm for the samples built with
higher current (220 A) and wider oscillation width. Tensile testing revealed that increasing 40 times the oxygen
levels in the shielding environment does not affect the tensile strength significantly.
Welding Engineering and Laser Processing Centre, Cranfield University, Cranfield, United Kingdom.
1
2 CABALLERO ET AL.
during arc deposition, and titanium experiences oxidation repetitive thermal cycles characteristic of WAAM proces-
during the WAAM process.5 sing. It was found that most of the oxidation takes place in the
The formation of the Alpha Case during WAAM of tita- solid state after deposition. In addition, it was concluded that
nium is of interest to determine the extent of damage by the observation of surface color does not suffice to assess the
oxidation phenomena. However, most of the research done to degree of oxidation, as the color developed depends on the
date regarding the formation of the Alpha Case has been surface quality too. Most of the trials performed in this study
focused on the isothermal oxidation of titanium in ambient air did not correspond to actual WAAM deposition conditions
at different exposure times. and no direct correlation was established between the degree
Alpha Case thicknesses of 300 and 72 lm at 850C for 20 of oxidation and the different variables that define a WAAM
and 2 h, respectively, have been found,6 proving how the process, such as amount of current, deposition strategy, and
thickness of the Alpha Case increases by increasing the ox- number of deposited layers (thermal cycles). The degree of
idation time. In addition, another study4 obtained a thickness oxidation damage such as the formation of Alpha Case was
of 60 lm for a 24 h heat treatment at 800C. Comparison of not considered or characterized either.
these two previous results allows the significant role of All the information available to date regarding titanium
temperature during the oxidation process to be established. discoloration is mainly focused on welding process and a
Increasing the temperature from 800C to 850C produced very small study has been done for additive-based pro-
similar values of the Alpha Case (72 and 60 lm) by using cesses. Moreover, oxide scale and Alpha Case characteriza-
92% less oxidation time. This allows us to assume an expo- tion are dedicated to welding processes and not to additive
nential effect that temperature has on oxidation (diffusion) manufacturing. The effect of oxidation on repetitive thermal
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processes as compared with time. The literature does not cycles typical of the WAAM process and different levels of
report Alpha Case characterization >850C, and since the oxygen contamination in the shielding environment needs to
WAAM process involves fusion of the material, the effect of be further characterized. Ti-6Al-4V by WAAM oxidation
higher temperatures on the depth of penetration of oxygen phenomena is discussed in detail in this article.
still needs to be investigated.
The different surface colors developed during welding of
Ti-6Al-4V, as consequence of oxidation, have been used as Materials and Methods
an indicator of the degree of oxygen contamination under-
Constant oxygen level in the shielding
gone by the material as a consequence of the fusion welding
environment—different deposition parameters
process. Several studies have been conducted before to relate
the amount of air contamination with the surface color de- These experiments were performed in an inflatable tent
veloped in titanium welding. using a constant oxygen purging level of 600 ppm. Fifteen
Previous studies have managed to characterize the surface titanium samples were manufactured using a six-axis indus-
color as a function of the level of oxygen of the shielding gas trial robot over 220 mm · 110 mm · 11 mm Ti-6Al-4V sub-
and the content of oxygen in a gas–tungsten–arc weld.7 Silver strates. The base plates were clamped on the four corners to
color weld surfaces (no apparent oxidation) were found when an aluminum backing table. Ti-6Al-4V filler wire of 1.2 mm
the air contamination in the argon shielding gas was 0%. In diameter was used for the deposition of the 200 mm long
contrast, for several air contamination levels up to 2% in the layers. The composition of the wire is indicated in Table 1.
shielding gas, a wide range of colors that changed as the Different robot paths or deposition strategies are used
oxide scale thickness increased were characterized, including in WAAM to achieve different geometries. Common ap-
straw, blue and pink-green mixtures on the weld surface, and proaches are single and oscillated passes (Fig. 1a). For single
a surface oxide scale thickness ranging from 10 to 120 nm, pass deposition, single weld beads are deposited one on top of
proving that any surface color different from silver is asso- the other until the required height is achieved. In the oscil-
ciated with a certain degree of oxidation. lated pass, the robot follows an oscillated path for every
Similar results were achieved for the discoloration of ti- single layer to achieve higher thickness than the single pass.
tanium during laser welding,8 where silver color welds with Each of these deposition strategies is expected to have dif-
pure argon were observed. However, in the latter case, a ferent thermal cycles as different thermal masses will pro-
purple/bluish color when adding 2% of oxygen to the duce different cooling rates on each deposited layer.
shielding gas was reported, in contrast with the former study Three different oscillation widths were chosen in this
wherein a pink/green mixture was found for the same oxygen work, 10, 30, and 50 mm, to assess the effect of different
content. This suggests that discoloration does not only de- thermal cycles and different thermal masses in the oxidation
pend on oxygen levels but also on different heat input used. process. A total of 20 layers were deposited for every sample
The effect of atmospheric contamination for additive using plasma-transferred arc and wire deposition and an in-
manufacture applications has also been studied.3 Tests were terlayer cooling time of 60 s. Within each oscillation value,
conducted in bead-on-plate welds and in Ti-6Al-4V bars five different currents were used. Table 2 gives the parame-
clamped between two electrodes to simulate the condition of ters used during the process.
Table 1. The Chemical Composition of the Ti-6Al-4V Filler Wire Used in Weight%
Ti Fe N Al O H V Y C Others
BAL 0.18 0.011 6.08 0.16 0.0017 4.00 <0.0010 0.035 <0.05
BAL, balance.
Ti-6Al-4V OXIDATION DURING WAAM 3
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FIG. 1. (a) Schematic representation of different deposition strategies used in this work showing different robot paths for
every single layer, (b) tensile test coupon geometry, (c) locations for tensile test coupons extraction.
Different oxygen levels in the shielding of investigating whether the oxygen content in the filler alloy
environment—constant deposition parameters has a significant effect on oxidation.
To investigate the effect of oxygen level in the shielding The 180 mm long single pass samples, of 20 layers, were
environment on oxidation, single pass deposited samples deposited on 200 mm · 110 mm · 10 mm Ti-6Al-4V sub-
were manufactured in a rigid sealed chamber. A Migatronic strates, using an interlayer cooling time of 60 s. The base
plasma power supply was used for deposition. Three differ- plates were clamped on the four corners to an aluminum
ent levels of oxygen were used, 40, 600, and 4000 ppm. Six backing plate. All the samples in this set of trials were
samples were built in this way. Three of them were manu- manufactured with a constant current of 145 A, and the same
factured with the standard Ti-6Al-4V filler wire, the same as deposition parameters are described in Table 2.
described in the previous section (Table 1), and another three For the oxygen level of 40 ppm, an extra sample was
samples were manufactured using low oxygen Ti-6Al-4V manufactured to assess how changes in both temperature
filler wire (according to specification AMS 4956, O £ 0.08%). and time affect the oxidation process. For this sample, to get
Trials with the low oxygen wire were designed with the aim higher temperatures, the interlayer cooling time was de-
creased to 30 s, while the length was decreased from 180 to
150 mm.
Table 2. Deposition Parameters Two 240 mm · 160 mm · 8 mm size single pass samples
for the Samples Done in the Tent were also manufactured using the same deposition parame-
ters at low and high levels of oxygen in the shielding envi-
Oscillation width (mm) Current (A) Voltage (V) ronment, which were 100 and 4000 ppm, respectively. The
10, 30, 50 145 18.3 inflatable shielding tent was used for this purpose. Tensile
160 19 test coupons were machined out of these samples to assess the
180 20 effect of different oxygen levels on the tensile properties of
200 21 the build.
220 22
Travel speed (mm/s) 4
Wire feed speed (m/min) 1.6 Samples processing
Plasma gas flow rate 1 L/min Since the surface color of the samples has previously
Shielding gas flow rate 10 L/min
Torch stand off 8 mm been related to the degree of oxidation, a qualitative visual
inspection was carried out. Transverse cuts were made in all
4 CABALLERO ET AL.
Metallographic characterization
of six vertically oriented and six horizontally oriented sam-
ples were extracted for subsequent machining and tensile The relationship between the oxygen diffusion zone (Al-
testing. Coupon dimensions are indicated in Figure 1b. Static pha Case) and the number of deposited layers (sample height)
tensile test was carried out following the BS EN 2002-1:2005 is shown in Figure 4. In all samples, the same behavior is
standard10 using an electromechanical Instron 5500R frame observed. Oxidation is always more significant in the region
with a load cell of 100 kN and a strain rate of 1 mm/min. of the first deposited layers.
FIG. 2. Visual aspect of samples showing the discoloration inherent to the process. Color images available online at
www.liebertpub.com/3dp
Ti-6Al-4V OXIDATION DURING WAAM 5
FIG. 3. Samples built with same deposition parameters except for interlayer cooling time and length (a) 60 s, 180 mm total
sample length; (b) 30 s, 150 mm total sample length. Color images available online at www.liebertpub.com/3dp
The Alpha Case thicknesses measured by OM observa- The oxide scale at the top of a random deposited layer of a
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tions for different oscillation widths and currents are shown sample built at 600 ppm is presented in Figure 6. In this re-
in Figure 5a. Higher current and oscillation width produce gion, the scales are very thin and discontinuous.
deeper Alpha Case. The maximum value for Alpha Case
thickness was *200 lm. Tensile mechanical testing
The single pass samples manufactured at three differ-
ent levels of oxygen and same deposition parameters show Table 3 gives the proof strength (PS), ultimate tensile
a deeper Alpha Case when the content of oxygen in the strength (UTS), and elongation percentage results obtained
shielding environment is higher. No significant difference from the tensile test of the samples built to assess the effect
can be observed comparing the samples manufactured with of different oxygen levels on tensile properties. Under both
standard and low oxygen wire. These results are shown in conditions, PS and UTS do not change significantly by varying
Figure 5b. the oxygen level. The sample built with 4000 ppm of oxygen
in the shielding environment only shows an increase of
*30 MPa in PS and UTS as compared with the sample built at
SEM characterization
100 ppm. For elongation, comparing the average values,
From SEM observations, it is found that oxide scales are higher levels of oxygen in the shielding environment produced
thicker in the area of the first few deposited layers. These a drop in ductility from 19% at 100 ppm to 15% at 4000 ppm.
features were found in every sample and they are shown in The same trend is observed for the direction-specific results.
Figure 4. It is also possible to see that the scale shows a The condition with the lowest ductility (*10%) corre-
multilayered structure. sponds to the samples taken in a direction parallel to the
FIG. 4. Alpha Case depth and oxide scale thickness variation with sample height (deposited layers) left: deeper Alpha
Case at the bottom of the sample; right: SEM images of the oxide scale at the first and last deposited layers region. Arrows
indicate the oxide scale and the multilayered structure. SEM, scanning electron microscopy.
6 CABALLERO ET AL.
Discussion
A gray and white discoloration on the surface of the
samples is associated with a thick oxide scale that is formed
as a consequence of the oxidation during deposition, as it
has been indicated previously in other studies11 (Fig. 2). The
experiments carried out with different oscillation widths
caused a visible gray/white oxidation of titanium samples on
the surfaces, despite the relatively low oxygen level in the
shielding environment (600 ppm). This suggests that tem-
perature and exposure time play more important roles than
oxygen levels during the WAAM oxidation process. The
repetitive deposition of molten material during WAAM, to-
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and exposure times are high enough, even if the oxygen levels the same thickness ranges are obtained within each oxygen
are low. level. This is due to the existing oxygen concentration gra-
Results described so far match the results found in the dient between the wire and the exposed surface of titanium to
literature. Different surface colors were identified by differ- oxygen. As soon as the temperature increases >500C, the
ent researchers7,8 as a consequence of different heat input and concentration of oxygen at the surface will reach the solu-
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thermal cycles, regardless of the fact that same air contami- bility limit in alpha phase (14 wt.%)12 while the concentra-
nation levels in the shielding environment were used. Fig- tion in the standard wire is around 0.16 wt.%. Since the
ure 4 helps to verify once again, that temperature and time oxygen can only diffuse from high to low concentration re-
play an important role in oxidation. Both oxide scale and gions, it can be suggested that it will not diffuse from the bulk
Alpha Case are thicker in the region of the first deposited of the sample to the surface. Therefore, the content of oxygen
layers, as a consequence of an exposure of these layers to a in the wire does not have a significant effect on Alpha Case
higher number of thermal cycles. thickness.
Although the visual aspect of all samples is very similar Figure 6 shows the thickness of the oxide scales at the top
(Fig. 2), a significant difference can be observed in terms of of a deposited layer at 600 ppm is *0.5 lm. It has been
Alpha Case thickness (Fig. 5a). This is in line with the pre- reported3,7 that when an autogenous welding pass, with a
vious observations,3,11 wherein the surface color alone can- proper shielding, is done on a colored weld, the coloring
not be used to assess the degree of oxidation. The minimum disappears. This means that the surface oxide scale is dis-
value of Alpha Case found in the oscillated samples with a solved during the subsequent weld pass, suggesting that the
constant oxygen level of 600 ppm was of 30 lm, whereas the oxygen released from the TiO2 might either go into the at-
maximum value was *200 lm. Hence, it can be stated that mosphere or into the weld metal.7 In the latter case, it is
visual appearance of WAAM deposited Ti-6Al-4V is not possible to estimate the increase of oxygen content in a newly
enough to assess the effect of oxidation. deposited layer based on the mentioned measurements.
Results presented in Figure 5a suggest that the thermal As previously established,1 each deposited layer by
mass of the samples plays an important role in the Alpha Case WAAM has a height of *1.2 mm (1200 lm). Hence, the
formation. It is evident that higher oscillation width means percentage of each new layer formed by the oxide scale can
more material deposited. If the amount of mass being heated be given in terms of a volumetric ratio.
is greater, it means that more heat will be retained by the For the purpose of this work, a single deposited layer and
component during the process. Hence, temperature will be the oxide scale will be assumed to be concentric half circles
higher for a longer time. This condition gives more time for with a radius of 1200 lm and 1200 lm + 0.5 lm = 1200.5 lm,
the oxygen to diffuse into the bulk, creating a deeper Alpha respectively, and the length will be assumed to be the length
Case. Higher currents generate deeper Alpha Case because of of the samples used in this study, 180 mm. The volumetric
the higher heat input associated with it that leads to a higher ratio percentage between the oxide scale and a single de-
temperature during the process. These experiments with posited layer is then equal to 0.08%. Assuming that all the
constant oxygen content in the shielding environment but oxide scale is formed by oxygen, it would represent an in-
with different thermal cycles demonstrate that the former has crease of 800 ppm of oxygen content in the deposited metal.
a small role in oxidation as compared with the latter. In the real process, this content could be much less as the
Since the oxidation of titanium during WAAM is a diffu- oxide scale is not 100% oxygen and it is possible that not all
sion phenomenon, there is mass transport involved in the of the scale is diluted into the weld pool as some percentage
formation of the Alpha Case. Once the oxide scale is formed may vaporize. Hence, potential dissolution of the oxide scale
by adsorption of oxygen, it will start to diffuse to the bulk of during deposition of each new layer is not expected to have a
the material following the concentration gradient. Higher great influence on tensile strength. Tensile test results allow
levels of oxygen in the shielding environment provide more us to analyze this aspect in more detail.
oxygen readily available to maintain the concentration gra- Results presented in Table 3 show that the oxygen content
dient and to carry on with the diffusion flux, generating in the shielding environment does not have a significant ef-
deeper Alpha Cases (Fig. 5b). fect on the mechanical strength. The 30 MPa increment for
When the thickness is compared between the standard the sample built under a 4000 ppm atmosphere is likely to be
filler wire and low oxygen consumable, it can be seen that caused by atomic oxygen becoming part of the bulk as a
there is no significant difference in the oxidation behavior; consequence of a new layer being deposited over an
8 CABALLERO ET AL.
already oxidized previous layer (as explained in the previous factured Ti-6Al-4V. Metall Mater Trans A 2013;44:968–
section). It is expected that a thicker oxide scale exists at the 977.
top of every single layer for a shielding environment of 2. Zabler S. Interstitial oxygen diffusion hardening—a prac-
4000 ppm in contrast to a layer built under a 100 ppm at- tical route for the surface protection of titanium. Mater
mosphere. Hence, a higher concentration of oxygen (in the Charact 2011;62:1205–1213.
form of oxide scale) is available to dissolve into solid solution 3. Hoye N. Characterisation of Ti-6Al-4V deposits produced
as an interstitial element. Increasing the levels of interstitial by Arc-wire based additive manufacture. PhD thesis, Uni-
oxygen results in higher strength and lower ductility.13 versity of Wollongong, 2014.
It is important to highlight that even though an increase of 4. Yue L. Wang Z, Li L. Material morphological character-
oxygen caused a maximum reduction of elongation down to istics in laser ablation of alpha case from titanium alloy.
Appl Surf Sci 2012;258:8065–8071.
10% (horizontal direction of the 4000 ppm sample), this
5. Ding J, Colegrove P, Martina F, et al. Development of a
value still remains within the requirements specified by
laminar flow local shielding device for wire+arc additive
ASTM B265-15,14 which establishes a minimum of 10% for manufacture. J Mater Process Technol 2015;226:99–105.
the elongation. 6. Dong H, Li XY. Oxygen boost diffusion for the deep-case
hardening of titanium alloys. Mater Sci Eng A 2000;280:
Conclusions 303–310.
In this study, the effect of oxygen diffusion (oxidation) 7. Maak P. The Effect of Air Contamination in the Argon
during WAAM of Ti-6Al-4V has been investigated. From the Shielding Gas on the Mechanical Properties of Titanium
Gas-Tungsten-Arc Welds. Chalk River, Canada: Atomic
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