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Meeting 2022 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing for Energy Applications IV
Presentation Title In-situ Powder-directed Energy Process Control for Additively Manufactured Multi-layer, Functionally Graded Components
Author(s) Calvin M. Downey, Luis Nunez, Isabella van Rooyen, Indrajit Charit, Michael Maughan, Edward Herderick
On-Site Speaker (Planned) Calvin M. Downey
Abstract Scope Harsh environments require advanced materials possessing high-temperature mechanical strength, corrosion resistance, and irradiation resistance. Claddings offer improvements over existing structural materials with protective layers over a bulk component. Additive manufacturing (AM) presents novel blown-powder directed energy deposition (DED) fabrication technologies, including laser-engineered-net-shaping (LENS) and Trumpf hybrid industrial machines. Process control in DED, such as laser heat input and in-situ material composition, make this method unique for overcoming issues such as layer delamination and brittle-phase nucleation. This study investigates DED-fabricated multi-layer bi-metals and compositionally functionally graded materials (FGMs) for 316L stainless steel, Inconel, and Cobalt-based alloys. Multi-layer clad builds are analyzed with x-ray diffraction to allow compositional phase control at the interlayer. Various combinations of FGMs are fabricated to 5–20% grades per layer. Electron microscopy, energy dispersive x-ray spectroscopy, and microhardness tests determine microstructure and preliminary mechanical behavior.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Powder Materials, Nuclear Materials


3D Ink-extrusion Printing of Thermoelectric Materials onto Heat Exchangers
3D Printing Energetics for Gun Propulsion Technology
Additive Manufacturing Topology Optimization and Materials Testing at Westinghouse
Advanced Manufacturing for the Development of Advanced In-pile Sensors and Instrumentation
Ballistic Additive Manufacturing -- Versatile Solid-state Fabrication
Characterization and Testing of Additively Manufactured T-91 Ferritic/Martensitic Material
Co-design of Parts and Processing for Additively Manufactured Heat Exchangers
Compositionally Graded Joint of 316L Stainless Steel to A508 Low Alloy Steel by Additive Manufacturing
Data-driven Modeling for Microstructure-property Relationships of 17-4 Stainless Steel
Effect of Microstructural Features on High Temperature Strength and Ductility of Selective Laser Melted Ni-base Superalloy
Effective Sensitization Treatment for High-performance Steel Parts Made by Laser Powder Bed Fusion
Effects of Processing Conditions on Microstructure of Metals Produced via Laser Powder Bed Fusion – A Case Study on Pure Nickel
Elevated Temperature Deformation Behavior of Al-Cu-Ce(-Zr) Alloys Produced by Laser Powder Bed Fusion Process
Evaluation of Tensile Strength and Microstructure of 304L Stainless Steel Repaired via Additive Friction Stir Deposition
High Substrate Heating (up to 500 degC) in Laser Powder Bed Fusion of High-strength Superalloys and Its Implications
Implications of Zr Additions for High-temperature Performance of Additively Manufactured Aluminum Alloys
In-situ Powder-directed Energy Process Control for Additively Manufactured Multi-layer, Functionally Graded Components
J-10: Investigation in Multi-layer and Multi-element Alloy Wire-arc Additive Manufacturing Cladding
J-11: Microstructural and Mechanical Investigation of IN718 Nickel-based Superalloy Fabricated via Laser-based Additive Manufacturing (LBAM)
J-12: Microstructure Evolution and Mechanical Properties of Selective Laser Melted SB-CoNi-10 Superalloy
J-13: Printing Nano Inks and Process Control for Plasma Jet Printer
J-14: Process-property Relationship for Fabricating Complex Heat Exchanger Geometry via Laser Powder Bed Fusion Additive Manufacturing
J-15: Quantifying Equiaxed Versus Epitaxial Solidification in CMSX-4 Single Crystal Superalloy Processed by Laser Powder Bed Fusion Using Single-tracks
J-16; Understanding Microstructure Evolution of High Temperature Ni Alloys Across Additive Manufacturing Processes
J-17: Understanding Process-structure-property Linkages in Electron Beam Melted Haynes 282
J-18: Understanding the Process-structure-property Correlation in Additively Manufactured IN718 Alloy
J-8: Creep Resistance of Al-Ce Binary Alloys Produced by Casting and Additive Manufacturing
Light on: In Situ Investigation of Structural Transformation of Additive Manufactured Aluminum Alloys Using Synchrotron Methods
Mechanical and Corrosion Properties of Friction Surfaced 304L Stainless Steel for Crack Repair
NOW ON-DEMAND ONLY - Design of Graded Transition Joints between Grade 91 Ferritic/Martensitic Steel and 347 Austenitic Stainless Steels with Non-linear Composition Variation Using Integrated Computational Materials Engineering (ICME) Approach
NOW ON-DEMAND ONLY - Direct Ink Writing of Ultra High Temperature Ceramics
NOW ON-DEMAND ONLY – Identification of Nanoparticles Dispersion Mechanism in 316L Metal Matrix Composite Additively Manufactured by Hybrid Process of Jetting and Laser Powder Bed Fusion
Optimization, Processing and Characterization of a Crack-resistant High-gamma Prime Superalloy for Additive Manufacturing in Power Generation Applications
Oxide Dispersion Strengthened Stainless Steel by Reactive Additive Manufacturing
Process-aware Design Optimization Methods for Metal Additive Manufacturing
Process Maps Using Fluid Dynamics Models in Single-laser Tracks for Additive Manufacturing
Recent Advancements in SPPARKS Metal Additive Manufacturing Simulation Capabilities
Relating Laser Scanning Effects to Cracking and Grain Structure of High-strength Superalloys
Surface Roughness of Metal Additive-manufactured Single-track Clads
The Creep and Corrosion Performance of AM303, an Elevated Temperature Ni-superalloy Designed for Direct Metal Laser Melting
The Microstructure, Mechanical, and Physical Properties of Additively Manufactured 316H Stainless Steel Lattices
Topological Optimization of CoCrMo Lattice Structures Fabricated by Laser Powder Bed Fusion

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