CRC 1368 – Oxygen-free production – B03 chemical mechanismen in titanium machining

During the machining of titanium materials, the high process forces and temperatures combined with the oxygen present in the ambient air cause oxidation processes on the tool, workpiece and chips. These lead to increased oxidation wear and thus limit the process performance. At the same time, oxidation changes both the edge zone properties of the components and the chemical composition of the tool and chips, which can have a negative impact on recyclability. However, the underlying interactions and mechanisms are not yet fully understood and therefore form the starting point for the investigations in the project.

Objectives

The objective of subproject B03 is to investigate the fundamental relationships between the oxygen content of the ambient atmosphere and the resulting effects on chip formation, thermomechanical stress, tool wear, and the properties of the manufactured components and chips. By understanding these interactions, specific ways to increase process performance can be figured out. Moreover, approaches to improve energy and resource efficiency will be figured out to make a sustainable contribution to the further development of oxygen-free production technologies.

Benefits

The project involves the development of an innovative machining technology that prevents oxidation wear by using an oxygen-free atmosphere, thereby significantly increasing the tool life. The reduced process forces and improved chip formation result in more efficient and stable machining, especially with demanding materials such as titanium. Another key advantage is the significant reduction in the oxygen content of the chips, which enables the material to be completely recycled. The project thus contributes to both increased resource efficiency and sustainable and economical production in the metalworking industry.

Approach

The project creates a practically oxygen-free atmosphere by replacing the air with a gas mixture of argon and silane during machining. By directly comparing chip formation, thermomechanical stress and tool wear in an oxygen-free atmosphere with machining in air, the effects of oxygen are quantified and the potential of oxygen-free manufacturing is determined.

High-speed analyses of chip formation enable a deep understanding of the interactions between the atmosphere, chip formation and surface generation on the workpiece. In cooperation with institutes at Leibniz University Hannover and Clausthal University of Technology, the chemical reactions and reaction products are also being investigated, thereby specifically connecting manufacturing technology and chemistry.

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Contact Florian Schaper via email at schaper@ifw.uni.hannover.de or by phone at +49 511 762 18337.