Additive Manufacturing for Energy Applications V: Processes and Optimization II
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS Structural Materials Division, TMS: Additive Manufacturing Committee, TMS: Nuclear Materials Committee
Program Organizers: Isabella Van Rooyen, Pacific Northwest National Laboratory; Subhashish Meher, Pacific Northwest National Laboratory; Xiaoyuan Lou, Purdue University; Kumar Sridharan, University of Wisconsin-Madison; Michael Kirka, Oak Ridge National Laboratory; Yi Xie, Purdue University
Thursday 2:00 PM
March 23, 2023
Room: 23A
Location: SDCC
Session Chair: Yi Xie, Purdue University
2:00 PM Introductory Comments
2:05 PM Invited
Enabling Part-Scale Scanwise Process Simulation of Laser Powder Bed Fusion by Combining Matrix-free Finite Element Modeling, Adaptive Remeshing, and GPU Computing: Albert To1; Alaa Olleak1; Florian Dugast1; 1University of Pittsburgh
This work proposes to combine matrix-free finite element modeling (FEM), adaptive remeshing, and graphical processing unit (GPU) computing to enable scanwise process simulation of the Laser Powder Bed Fusion (L-PBF) process with temperature-dependent thermophysical properties at the part scale. Compared to the conventional FEM using the global stiffness approach and a uniform mesh running on 10 CPU cores, L-PBF process simulation based on the proposed methodology running on a GPU card with 5,120 Compute Unified Device Architecture (CUDA) cores enables a speedup of over 10,000x. This significant speedup facilitates detailed thermal history and melt pool geometry predictions at high resolution for centimeter-scale parts within days of computation time. Several parts consisting of various geometric features are simulated to reveal the effects of scan strategy and local geometry on melt pool size variation. The development of this simulator is expected to impact simulation-based qualification of L-PBF parts.
2:40 PM
Inspection Results from a Real Time Non-Destructive Evaluation of 3D Manufactured Metal Parts: Araz Yacoubian1; 1LER Technologies Inc.
Additive manufacturing, such as laser sintering or melting of additive layers can produce parts rapidly at small volume and in a factory setting. To make the parts having nuclear quality and yet low cost, a real-time non-destructive evaluation (NDE) technique is required to detect defects while they are being manufactured. The NDE technique to be presented utilizes a multimodal optical sensor unit that is incorporated in a direct metal laser sintering machine to capture defects in real-time such that immediate corrective action by the machine can be taken. It also provides parameters that enable the prediction if the part is of nuclear quality. The sensor produces a defect map as the part is being printed. Real-time NDE results while AM parts are being manufactured in a powder-bed machine will be presented. Detected defects will be compared to actual flaws.
3:00 PM
Assessment of Laser Powder Bed Melting for Obtaining Ferritic/Martensitic ODS: Lucas Autones1; Yann De Carlan1; Pascal Aubry1; Joel Ribis1; Hadrien Leguy1; Alexandre Legris1; Jean Henry1; 1CEA
Ferritic/martensitic ODS (Oxide Dispersion Strengthened) steels are being considered as structural materials for fusion reactors or for the cladding of GEN IV reactors. These materials present an extremely dense distribution of nano-oxides. They are obtained by mechanical alloying and hot consolidation. It would also be very interesting to be able to manufacture components directly by additive manufacturing. From the results obtained with conventional ODS powders or with a mixture of a pre-alloyed powder with nano-oxides, this presentation will show the performances that can be expected by LPBM for the fabrication of ODS. The real potential of Laser Additive Manufacturing for ferritic ODS will be presented and discussed.
3:20 PM
Additive Manufacturing of an Oxide Dispersion Strengthened Nickel-based Alloy for Molten Salt Reactor Application Using Hastelloy N Powder: Fedi Fehri1; Matthew deJong1; Sourabh Saptarshi1; Timothy Horn1; Djamel Kaoumi1; 1North Carolina State University
Ni-based alloy now known as Hastelloy-N was developed for use as a structural material for molten salt reactor applications for its good resistance to molten salt corrosion. However, its radiation resistance was limited especially in terms of swelling. A new oxide dispersion strengthened (ODS) version of that alloy is being developed at lab scale using custom made Hastelloy-N powder. This is done using Hastelloy N powder mechanically mixed with additions of Y2O3 powder and either Ti or Zr powders then consolidated through LPBF additive manufacturing. Microstructural characterization of the samples is conducted using transmission electron microscopy and Chemi-STEM. The process resulted in the formation of the oxide dispersion. The oxide particle size distribution, number density and volumetric density was determined for the different samples. A comparison with samples obtained from a different consolidation route consisting of cryo-milling the powder mixtures, cold pressing and sintering is also provided.
3:40 PM Break
3:55 PM
Wire-Arc Additive Manufacturing of Soft-magnetic Alloy: Soumyajit Koley1; Kuladeep Rajamudili1; Supriyo Ganguly1; 1Cranfield University
Fe-Si alloy with Si content more than 6 wt.% and Fe-49Co-2V alloy demonstrate superior magnetic permeability and high electrical resistivity compared to commercial electrical steel. A near zero magnetostriction is also achieved with Fe-Si alloy. The challenge is to large-scale production of these alloy through traditional routes owing to brittle phase formation during slow cooling. This renders the alloy susceptible to cracking under any deformation process such as hot or cold rolling. An attempt has been made to produce Fe-6.9Si / Fe-49Co-2V alloy using wire-arc additive manufacturing (WAAM) route. Self-standing crack-free wall was manufactured using a conventional plasma arc torch with cold wire feeding attachment. Electro-magnetic measurements carried out on the deposits indicated magnetic permeability at per with the conventionally prepared alloy. Post deposition solution annealing treatment improved the magnetic permeability appreciably.
4:15 PM
Effect of Precipitate Wettability on Nanoscale Oxide Precipitation of Additively Manufactured FeCrAl via In Situ Oxidation: Ty Austin1; Steven Zinkle1; Niyanth Sridharan2; 1University of Tennessee, Knoxville; 2Lincoln Electric
Oxide dispersion strengthened (ODS) FeCrAl alloys combine the improved high-temperature corrosion resistance provided by Al additions with the improved mechanical properties and irradiation resistance provided by fine nanoscale precipitate dispersions. Directed energy deposition (DED) additive manufacturing (AM) providing oxygen during powder consolidation allows for potential increased geometric complexity, local microstructure control, and part throughput while avoiding the pitfalls often plaguing conventional mechanical alloying (MA) based ODS manufacturing of batch-to-batch variability, long lead times, low throughput, and anisotropic mechanical properties. In our previous work DED AM manufacturing of ODS FeCrAl was capable of significant oxygen retention (0.067 wt%) and precipitate number densities (~1022 m-3) while maintaining acceptable part quality (part density > 99%). Unfortunately, significant amounts of oxide forming elements were wasted by precipitate agglomeration. This work examines the influence of Si, Ti, and O additions to improve oxide wettability and incorporation into the matrix of ODS FeCrAl produced using DED.
4:35 PM
An Additively Manufactured Integrated Heat Pipe and Heat Exchanger with Thermoelectric Devices: Donna Guillen1; Miu Lau2; Kari Perry1; Dennis Tucker1; Arin Preston1; Laura Ziegler1; 1Idaho National Laboratory; 2Boise State University
Thermoelectric devices are solid-state devices used to convert thermal energy to electrical energy. However, current deployment of these devices is limited by high manufacturing costs and low efficiency. Integrating a heat pipe-heat exchanger with the thermoelectric platform can eliminate thermal contact resistances and increase device performance. Additive manufacturing of the heat exchanger enables the fabrication of a compact device with an optimized configuration that cannot be readily produced by traditional manufacturing methods. The heat exchanger topology features a 3D printed triply periodic minimal surface that offers the potential for lighter weight structures. The heat pipes, heat exchanger and thermoelectric components are modelled using the Multiphysics Object Oriented Simulation Environment. The novel integration of the heat pipe, heat exchanger, and thermoelectric device can be applied to a myriad of thermal transport applications, including wind and solar energy, waste heat recovery, and heat removal systems.