The Effect of Wire Electrical Discharge Machining on the Fatigue Life of Ti-6Al-2Sn-4Zr-6Mo Aerospace Alloy

The paper details experimental data for the fatigue behaviour of aeroengine alloy Ti-6Al-2Sn-4Zr-6Mo following wire electrical discharge machining (WEDM), with minimum damage generator technology and optimised trim pass strategies. Comparative results for flank milled samples are also given together with associated micrographs detailing workpiece subsurface integrity and fracture initiation. Despite a marginally higher S-N response for the milled specimens compared to the wire machined samples when subject to a finishing regime, linear regression statistical analysis suggested no significant difference in performance at the 5% level based on slope responses. Micrographs showing sample crack initiation sites and fatigue crack growth paths suggest a 40- 50 μm altered zone in fracture surfaces for milled specimens with fatigue striations defining the crack path. For WEDM surfaces, crack initiation was in some cases due to defects below the machined surface, with secondary cracks probably due to local stresses.