Effects of the cross-wedge rolling parameters on the formability of Ti–6Al–4V alloy

Ti–6Al–4V alloy is an ideal material for gas turbine blades with high strength and low density. The application of the cross-wedge rolling (CWR) process for manufacturing Ti–6Al–4V alloy blade preforms has great innovative potential. In this study, isothermal hot compression tests with strain rates between 0.01 and 10 s−1 and deformation temperatures between 850 and 1050 °C were carried out. The constitutive equation was established and implemented into a 3D finite element (FE) model to analyze the formability of the CWR of Ti–6Al–4V alloy. Furthermore, CWR experiments were developed to verify the dependability of the FE simulation results and to investigate the influence of the process parameters on the formability of Ti–6Al–4V. The comprehensive results of the FE simulation and CWR experiments show that both the tool parameters and rolling temperature significantly affect the formability of the Ti–6Al–4V alloy. When the forming angle was 30° or 35°, the stretching angle was less than 7°, the area reduction was less than 72.4%, and the rolling temperature was 950 °C, The surface quality during the CWR process can be significantly improved.