Additive Manufacturing: Materials Design and Alloy Development IV: Rapid Development: High Temperature Alloys
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee, TMS: Integrated Computational Materials Engineering 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
Tuesday 8:00 AM
March 1, 2022
Room: 261A
Location: Anaheim Convention Center
Session Chair: James Saal, Citrine Informatics
8:00 AM
Composition-dependence of the Microstructural and Mechanical Properties of Co-Cr-Fe-Ni Multicomponent Alloys Fabricated by Directed Energy Deposition: Daniel Salas1; Ryan Saucier1; Tanner Kirk1; Sezer Picak1; Michael Elverud1; Raymundo Arróyave1; Ibrahim Karaman1; 1Texas A&M University
Quaternary Co-Cr-Fe-Ni alloys forming single phase disordered FCC structures and with a minimum elemental content of 10 at.% conform a family of medium entropy alloys that covers a vast compositional-space. An optimum exploration of such space for the design and discovery of novel FCC alloys with optimized mechanical properties requires a high-throughput methodology for both material selection and production. Firstly, CALPHAD-based calculations were employed for screening and delimiting the compositional-space of FCC-forming Co-Cr-Fe-Ni alloys and a k-medoids algorithm was used for composition selection. Following, printing parameters were optimized for obtaining fully dense builds and twenty different alloys were printed from elemental high-purity powders thanks to a laser engineered net shaping system equipped with four hoppers. Finally, the microstructural and mechanical properties of these materials were characterized in both as-printed and solution heat treated conditions, allowing us to establish relationships between composition, microstructure, and the mechanical response of Co-Cr-Fe-Ni alloys.
8:20 AM
Development of Metal-ceramic Hybrid Structure Using Additive Manufacturing Technology: Hyun-Gil Kim1; Sung Chan Yoo1; 1KAERI
The composite materials of metal and ceramic can be usefully used in various industries such as aerospace, nuclear, defense, and chemical. However, there are many difficulties in designing and manufacturing a metal-ceramic hybrid composite material with existing manufacturing technology. We conducted various attempts by applying the direct energy deposition (DED) method, one of the additive manufacturing technologies, as a method for realizing a metal-ceramic hybrid material. Specifically, SiC coating,ODS structure were implemented by printing ceramic particles on a metal base material, as well as a radiation shielding structure such as B4C was manufactured. The most important point in laminating the ceramic on the metal surface is how well the bonding force of interface is maintained. To solve this problem, the process conditions for making a compositionally graded structure in which a mixed layer between two materials is formed at the interface was studied.
8:40 AM
3D Printing of Ni-based Superalloys: Influence of Composition on Processability and Performance: Joseph Ghoussoub1; Yuanbo Tang1; Roger Reed1; 1University of Oxford
The processability and performance of nickel-based superalloys is studied. Many alloys -- some of existing (heritage) type but also other newly-designed ones -- are considered. A strong inter-dependence of alloy composition and cracking mechanism is demonstrated. The two dominant defect types found -- solidification cracks and solid-state ductility dip cracks -- are distinguished and quantified. Each alloy is characterized through novel electro thermal mechanical tests to elucidate the factors influencing their processability or lack thereof. Performance metrics such as strength, creep, oxidation and resistance to oxidation-assisted cracking are studied and contrasted with alloy processability. Several processability-performance trade-offs are identified. This work provides fundamental insights into the role of composition on the additive manufacturability and performance of high temperature nickel-based superalloys.
9:00 AM
Additively Manufactured 718 Ni Alloys with Oxide Nanoparticles: Benjamin Stegman1; Bo Yang1; Zhongxia Shang1; Jie Ding1; Tianyi Sun1; Jack Lopez2; William Jarosinski2; Haiyan Wang1; Xinghang Zhang1; 1Purdue University; 2Praxair Surface Technologies Inc.
While direct metal laser sintering (DMLS) has been thoroughly explored in many workhorse alloys, oxide dispersion strengthening (ODS) alternatives of these alloys have presently had little investigation. Here we report on an ODS alloy 718 (718) successfully developed by mixing oxide powders with control 718 powders to produce a homogeneous distribution of oxide nanoparticles, which then were used in the DMLS technique. This newly developed metal matrix composite (MMC) was investigated under various forms of material characterization, ranging from X-ray diffraction to transmission electron microscopy to analyze microstructures and chemistry from macroscale to nanoscale. This study reveals the prominent differences between control 718 and this new ODS alloy, and how the presence of oxide nanoparticles alters the microstructure and mechanical behaviors. This new processing technique demonstrates the possibilities of using DMLS to fabricate ODS alloys for applications in extreme environments.
9:20 AM Break
9:35 AM
Applications of a Subspace-inclusive Sampling Method for the Computational Design of Compositionally Graded Alloys: Marshall Allen1; Raymundo Arroyave1; Richard Malak1; 1Texas A&M University
Previously, the authors developed a compositionally graded alloy design algorithm that avoids common problems, such as deleterious phases, while optimizing for performance objectives. This previous methodology was limited in that it only sampled the interior of the composition space. Since even small amounts of additional alloying elements can introduce new deleterious phases, this characteristic often neglected potentially simpler solutions to otherwise unsolvable problems such as using a single component in a layer, or navigating a binary subsystem, and, consequently, discouraged adding elements to the state space. In this work, the authors developed a new sampling method that considers all subspaces of the composition state space. Ultimately, this advancement facilitates a complete investigation of the composition space and thereby more robust and flexible gradient design. This improved methodology could enable solutions for difficult problems like grading 6-4 titanium and aluminum alloys or grading for properties like stacking fault energy.
9:55 AM
Behavior of Coated Particles in Directed Energy Deposition: Sen Jiang1; Baolong Zheng1; David Svetlizky2; Yizhang Zhou1; Lorenzo Valdevit1; Noam Eliaz2; Enrique Lavernia3; Julie Schoenung1; 1University of California Irvine; 2Tel-Aviv University; 3National Academy of Engineering
ZnAl powder particles, encapsulated with metal coatings to prevent dissolution, can be introduced into aluminum alloys to form self-healing materials. However, in directed energy deposition (DED), the vaporization of Zn during the deposition process presents a challenge for retaining the integrity of the coated ZnAl particles in the final builds, due to the low boiling temperature of Zn. In this work, a COMSOL numerical simulation model was constructed to study the heat transfer and phase transformation for a coated particle floating in the aluminum alloy molten pool. Transient temperatures and phase fields were calculated, and particle residence times, defined as the time required for initiation of Zn vaporization, were determined for different coating thicknesses, molten pool temperatures, particle diameters and coating materials. The calculation results were used to determine the DED process windows for retaining the coated ZnAl particles in the final builds.