Additive Manufacturing: Materials Design and Alloy Development III -- Super Materials and Extreme Environments: Other Materials and Aspects
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee
Program Organizers: Behrang Poorganji, Morf3d; Hunter Martin, HRL Laboratories LLC; James Saal, Citrine Informatics; Orlando Rios, University of Tennessee; Atieh Moridi, Cornell University; Jiadong Gong, Questek Innovations LLC
Wednesday 8:30 AM
March 17, 2021
Room: RM 3
Location: TMS2021 Virtual
Session Chair: Jiadong Gong , QuesTek
8:30 AM Invited
Design of Novel Fe-based Bulk Metallic Glasses Enabled by Additive Manufacturing: Martin Walbruehl1; Jiayi Yan1; Ida Berglund1; Zaynab Mahbooba2; Abhinav Saboo2; 1QuesTek Europe AB; 2QuesTek Innovations
Bulk metallic glasses (BMGs) exhibit unique characteristics and may offer superior performance compared to conventional alloys, however; today’s BMGs are of limited industrial relevance due to thickness limitations intrinsic to traditional manufacturing methods. With Additive Manufacturing (AM), a unique capability to manufacture BMGs has become available as it combines the required cooling rates and exceeds the build limitations associated to traditional methods. While AM processing has been demonstrated in Zr-based BMGs, Fe-based alloys show limited printability as they suffer from cracking and porosity in the final build, preventing use in industrial applications. Integrated Computational Materials Engineering (ICME) is a key to understand the process-structure-property evolution within AM-builds mitigating the trade-off between printability and vitrification. An ICME-based modelling approach is used to design novel Fe-based BMGs tailored to harness AM specific opportunities and to overcome associated challenges.
9:00 AM
Understanding the Corrosion Mechanism of an Equimolar AlCoCrFeNi High-entropy Alloy Additively Manufactured by Electron Beam Melting: Kenta Yamanaka1; Hiroshi Shiratori2; Manami Mori3; Kazuyo Omura1; Tadashi Fujieda2; Kosuke Kuwabara2; Akihiko Chiba1; 1Tohoku University; 2Hitachi, Ltd.; 3National Institute of Technology, Sendai College
In this study, the corrosion behaviour and passive film characteristics of an equimolar AlCoCrFeNi HEA additively manufactured by electron beam melting (EBM) were investigated. The as-built specimen consisted of the BCC/B2 matrix and grain-boundary FCC phase, although the phase fraction varied along the build direction. Consequently, the EBM specimen shows better corrosion performance than a cast counterpart in terms of both corrosion and passivation current density, while the top part of EBM specimen does not represent an apparent passivity during anodic polarization in a 3.5 wt.% NaCl solution. The electrochemical impedance spectroscopy captured an enhanced charge transfer resistance and the formation of more protective passive film of the bottom part. The enrichment of Cr in the B2 phase during the post-melt high-temperature exposure in the EBM process was responsible for the improved stability of the passive film, suppressing the selective dissolution of the B2 phase in the bottom part.
9:20 AM
Design and Additive Manufacturing of Hastelloy C22 for Corrosive Environment: Somayeh Pasebani1; Dongqing Yan1; Alireza Torbati-Sarraf2; Behrang Poorganji3; Osman Ertorer4; O Isgor1; 1Oregon State University; 2LAM Research Corporation and University of Southern California; 3University of Waterloo; 4Oryx Advanced Materials, Inc
A Hastelloy C22 powder with the chemical composition of Ni-21.30Cr-13.36Mo-1.92Co-2.94W-3.85Fe-0.23Mn-0.3V(wt%) and particle size distribution of D10=23.8±0.3 μm, D50=37.5±0.2μm and D90=59.3±1.1 μm was used as a feedstock in a laser powder bed fusion process. Laser power, scanning speed, and layer thickness was varied in a nitrogen atmosphere. Optimization of the process led to the highest density and the lowest surface roughness. Following the optimization, the samples were heat-treated in nitrogen environment to obtain the required microstructure and mechanical properties. Chemical composition and/or post-laser fusion heat treatment were designed in the additive manufacturing process to achieve the required mechanical properties and corrosion resistance. Furthermore, electrochemical tests were conducted to assess the corrosion performance of the additively manufactured samples in selected corrosive environments. Microstructure, mechanical properties, and corrosion resistance of the additively manufactured samples are benchmarked against conventionally manufactured Hastelloy C22 specimens.
9:40 AM
Catalytic Inhibition of Metal Dusting by Cu – The Difference of Cast and AM Alloys: Anke Ulrich1; Clara Schlereth1; Katrin Jahns2; Ulrich Krupp3; Mathias Galetz1; 1DECHEMA-Forschungsinstitut; 2University of Applied Sciences Osnabrück; 3RWTH Aachen University
Metal dusting is an extreme aggressive form of high temperature corrosion in atmospheres with high C activities causing severe damage to plants e.g. in process industry. A decrease of maintenance and fast solutions in the case of damage are of extreme economic relevance. The latter leads to a great interest in additive manufacturing (AM) of spare parts on-site. Additionally, alloying of commonly used Ni-base materials with Cu was found to reduce the attack since the catalytic deposition of graphite or carbon on the metal and thereby the extremely fast-progressing metal loss is inhibited. Therefore, the metal dusting resistance of Cu-containing Ni-base alloys such as Alloy 400 is investigated in experiments under metal dusting conditions and pressures up to 18bar. The focus is on the difference between the performance of AM samples in comparison to cast alloys. Additionally, different surface pre-treatments were used for the AM samples.
10:00 AM
Correlating Data from Digital and Virtual Twins of Component Manufacturing via DED: Monica Salgueiro1; Carlos Gonzalez1; Camilo Prieto1; Bernardo Freire2; Mihail Babcinschi2; Joerg Willem3; Mustafa Megahed3; 1AIMEN; 2University of Coimbra; 3ESI Group
Additive manufacturing challenges stem from the number of adjustable parameters affecting the component quality. The complexity is amplified by the fact that printed features interact with process parameters affecting the outcome. Physics-based models explain the complexities of phenomena taking place and can be used for initial planning. The virtual twin cannot readily take the influence of printed features and process parameter drift into account. On-line monitors are considered as key tools towards quality assurance and forward feed control. The digital twin however does not necessarily explain the interdependencies of parameters and part quality unless it is combined with the virtual twin. This study utilizes virtual and digital twins of direct energy deposition. The digital twin confirms the virtual twin results. The collated data is used to extract a quick response model that is applied for forward feed control. The improved print quality is presented together with planned system extensions.
10:20 AM
Material Development Using RF Plasma: Nicolas Gobeil1; 1Tekna
Selecting metallic powders is a vital consideration in Additive Manufacturing, Metallic powders can be manufactured by many processes, but only a limited number can produce powders specifically designed for meeting the requirements of the various additive manufacturing (AM) technologies. This presentation will review the main techniques used to produce AM powders, namely gas atomization and plasma technologies. We will then focus on AM powder development by RF plasma.