This research work was focused on the application of powder metallurgy technology to the production of high-quality products from Ti6Al4V alloy (Ti64). The common way to produce structural parts from Ti64 alloy is hot forging. At present, the stock for forging is commonly manufactured from cast material. An attractive alternative for producing such billets can be powder metallurgy technology (P/M). The processing of compacts makes it possible to reduce the cost of production and leads to obtaining very good quality of the microstructure and properties. It is also very important, that this process can be realised using commercial processing lines for forming the cast stock.The proposed procedures of development and verification of the parameters of deformation of Ti6Al4V alloy compacts in open-die forging process were discussed. As the material under investigation, compacts obtained from elemental powders were applied. The compacts were nearly free from porosity, which was confirmed by computed tomography non-destructive tests. The numerical modeling of hot forming of the selected forging was performed based on the finite element method (FEM). Various combinations of forging conditions were simulated, however the range of parameters was in accordance with possibilities of the industrial line. The results of modeling were verified in the trials conducted in industrial conditions. The quality of the product was estimated by the examinations of the microstructure as well as hardness measurements. It was found, that forging of billet, manufactured with application of the proposed powder metallurgy technology, leads to obtaining a defect-free Ti6Al4V alloy part.Keywords: powder metallurgy, titanium alloys, hot forging, thermo-mechanical parameters, microstructure
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