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Meso-scale fatigue foil production October 2016 Mike Fitton RAL

Meso-scale fatigue foil production October 2016 Mike Fitton RAL. 8” Ti-6Al-4V bar Material purchased for 6 foils + 4 beam window domes. Before foils machined a small pip from bar centre is extracted to confirm microstructure using SEM + EBSD. Manufacture procedure

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Meso-scale fatigue foil production October 2016 Mike Fitton RAL

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  1. Meso-scale fatigue foil production • October 2016 • Mike Fitton • RAL

  2. 8” Ti-6Al-4V bar • Material purchased for 6 foils + 4 beam window domes • Before foils machined a small pip from bar centre is extracted to confirm microstructure using SEM + EBSD

  3. Manufacture procedure Foils rough machined to 1mm thick Stress relive (600°C for 2hrs) in high vacuum Foils final machine to 0.3mm thick Stress relive (600°C for 2hrs) in high vacuum Foils laser cut from support material

  4. Foils laser cut using very fine scanning laser. Same laser can be used to cut meso-scale cantilevers • All measured and in tolerance to drawing • Foils remained flat • Foils passed to Oxford for polishing and meso-cantilever cutting

  5. Initial polishing/lapping by Oxford using trial (0.4mm sheet material) • First trial polishing to 0.13mm  Foils have bent • Probably due to residual stress in sheet material. New trial with stress relived material. • Real samples from bar and already stress relieved so should be much less of a problem. • Might be necessary to polish both surfaces to balance stresses if stress reliving does not work or stress comes from lapping process

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