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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Advances in Titanium Technology
Presentation Title Modeling and Simulation Strategies of Micro-Casting from Titanium (Ti-6Al-4V) Swarf
Author(s) Arul Mozhi Varman Varman Jayaraman Palanivel, James Wainwright, Wojciech Suder, Sivarupan Tharmalingam, Konstantinos Georgarakis, Konstantinos Salonitis, Mark Jolly, Stewart Williams
On-Site Speaker (Planned) Arul Mozhi Varman Varman Jayaraman Palanivel
Abstract Scope One way of reducing the CO2 footprint for titanium alloys can be by the innovative re-use of machining by-products (swarf). This paper will present modeling and simulation for micro-sized casting in Ti-6Al-4V swarf, with the ultimate aim of the development of continuous cast wires as additive manufacturing feedstock. Finite Element (FE) modeling is employed to predict thermomechanical behaviour enabling optimisation of heat transfer coefficients for enhanced process control. Computational Fluid Dynamics (CFD) simulation is used to simulate melt flow within a micro-scale crucible to ensure reliable molten metal delivery. Using simulation tools enables rapid design iteration and process tuning without extensive trial-and-error experimentation. This work could contribute to circular economy practices and reinforces the role of digital twins in advancing net zero manufacturing goals in metal manufacturing processes.
Proceedings Inclusion? Planned:
Keywords Titanium, Modeling and Simulation, Sustainability

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A DEM-FEM Coupling Method for Simulation of Vibratory Peening of Ti6Al4V
Additive manufacturing of martensitic Ti-Nb
Al, slip planarity and fatigue performance in Ti alloys
Aspects of surface treatment via Femtosecond laser Micromachining on the Microstructure and Mechanical Properties Ti Alloys.
Assessing omega-phase precipitation in compositionally graded, sputter deposited Ti-V
Characterization of a Novel TWIP Titanium Alloy
Cold Dwell Fatigue Damage Mechanism Analysis Using Statistically Large Datasets Generated by Reflected Light Dark Field Microscopy and Electron Backscatter Diffraction
Contrasting Additively Manufactured and Arc-Melted Beta Titanium Alloys
Coupling Sieverts’ and Mechanical Testing: Hydrogen Behavior in Titanium Materials
Decoding microstructural anisotropy and mechanical response of hBN reinforced Ti matrix processed via selective Laser melting.
Deformation mechanisms in β and α phases during high-strain-rate compression of Ti-6Al-4V in mill-annealed condition
Deformation Studies in Dwell Fatigue and Creep Deformed Samples of Alloy Ti-6246
Design and strengthening mechanisms of a novel Ti-W alloying system
Development of a Novel Ti-6Al-4V based Alloy Design Guideline via Controlled β Phase Metastability
Development of as-processed novel titanium alloys exhibiting refined and uniform microstructures with very high strengths and an absence of residual stresses
Development of TiAl alloys: a future light-weight material for extreme condition
Dislocation Mechanisms in Titanium: Insights from Three-Dimensional Discrete Dislocation Dynamics Simulations
Dwell Fatigue and its Thermal Alleviation in MTR free Ti alloy, Ti 6242
Effect of Aging Parameters on Phase Evolution and Mechanical Performance of Laser-Deposited Ti-Fe Alloy.
Effect of Alpha Phase Evolution on Deformation Mechanisms in Metastable β Titanium Alloys
Effect of c/a ratio on mechanical properties under dynamic loads in (α+β) titanium alloys
Effect of varying titanium nitride fractions on high-temperature properties of titanium-titanium nitride metal matrix composites
Engineering Ti-6Al-4V Powders for Dual Enhancement in L-PBF Process: Achieving Superior Mechanical Properties via SiO₂-Coating and Cost Reduction via HDH Blending
Exploring low temperature sintering behaviors of Ti and TiH2 powders
Fatigue behaviour of novel titanium alloys
Grain Boundary α Formation in Ti-6Al-4V Fabricated via Laser-Based Powder Bed Fusion with Preheated Substrates
Hot Deformation of a Ti-Al-V-Fe Alloy in the α + β Phase Region
In-Situ Alloying of Ti-6Al-7Nb with Copper Using Laser Powder Bed Fusion for Enhanced Biocompatibility in Permanent Implants
Investigating the mechanical performance and microstructural evolution of functionally graded (FG) and non-functionally graded (NFG) titanium alloys produced through Field-Assisted Sintering Technology (FAST).
Investigation of SiC/Ti Porous Composites
Leveraging Precipitation Hardening Aging Treatments on Thermo-hydrogen Refined AM Ti-6Al-4V Microstructures
Mechanofusion-based Fabrication of Y₂O₃-reinforced Ti-6Al-4V Powders for L-PBF process
Microalloying With Transition Metals as a Key Strategy to Maximize the Strength–Ductility Combination in Dilute Titanium Alloys
Microscale Strain Localization and Interface Damage in Alpha + Beta Ti-6Al-4V
Microstructural Modification and Mechanical Property Optimization in Ti-5553 Alloy
Microstructure - Property Correlation in Additively Manufactured TiAl Intermetallic Alloy
Microstructure evolution and mechanical performance of cold metal transfer-based wire-arc additively manufactured titanium alloys
Modeling and Simulation Strategies of Micro-Casting from Titanium (Ti-6Al-4V) Swarf
Negative/zero/positive thermal expansion alloys
New optimization routine for Functionally Graded Ceramic Metal Matrix Composite (FG-CMMC) based High-Speed Vehicle Outer Mold Line
On the reaction kinetics and microstructural evolution during gaseous nitriding of metastable beta titanium alloys
On the Variant Selections in (α+β) Titanium Alloys by In-Situ High Temperature X-Ray Texture Measurement
Optimization of Ti-6Al-4V alloy obtained by additive manufacturing using direct wire deposition for critical aerospace applications
Oxidation mechanisms in dilute Ti alloys
Paired Analysis of Crack Initiation Sites in Dwell-Fatigued α/β Titanium Alloys
Phenomenology and Mechanisms of Room Temperature Creep in Ti Alloys
Porosity Guided Improved Mechanical Properties Through Hot Isostatic Pressing treatment in Laser Powder Bed Fusion of Ti-6Al-4V
Retained Ductility in Ti-6Al-4V After Undergoing Cyclic Bending Under Tension
Role of kink bands in enhancing ductility in laser powder bed fusion processed metastable beta Ti alloy
Room temperature cold creep of Ti studied by constant contact pressure nanoindentation
Room Temperature Creep Behavior in Alloy Ti6246: A Cantilever Bending Creep Approach
Tailoring the beta-omega compositional partitioning to achieve high strength and ductility in laser powder bed fusion processed metastable beta Ti alloys (invited)
Temperature dependent elastic constants of powder metallurgy processed Ti6242-Ti4822 composites
The anisotropy of deformation twinning in bcc materials: Mechanical loading, temperature effect, and twin–twin interaction
The Development of a New Metastable β Titanium Alloy Processed with Hot Isostatic Pressing
The Effect of Temperature on the Mechanical Behaviour of Ti64 at Low Strain Rates
The Effects of Torch Shielding Gas During Wire-Arc Directed Energy Deposition of Grade 2 Commercially Pure Titanium
Thermochemical Surface Engineering of Titanium Alloys
Ti-Fe Alloys via Powder Metallurgy for Cost-Effective Civilian Applications
Tuning microstructural heterogeneity to progressively trigger different deformation mechanisms in AM processed Ti alloys
Understanding Nanostructures in Metastable Beta Titanium Alloys
Understanding the Effect of Al on Strain Rate Sensitivity in Ti Alloys
Understanding Ti-6Al-4V deformation micro-mechanisms in extreme conditions
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