Additive Manufacturing of Large-scale Metallic Components: Poster Session
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee
Program Organizers: Sneha Prabha Narra, Carnegie Mellon University; Sougata Roy, University of North Dakota; Andrzej Nycz, Oak Ridge National Laboratory; Yousub Lee, Oak Ridge National Laboratory; Chantal Sudbrack, National Energy Technology Laboratory; Albert To, University of Pittsburgh

Tuesday 5:30 PM
March 1, 2022
Room: Exhibit Hall C
Location: Anaheim Convention Center

J-19: Hybrid Additive Manufacturing of the Ni Super Alloy Inconel 718: Matjaz Godec1; Simon Malej1; Darja Feizpour1; Črtomir Donik1; Matej Balažic2; Damjan Klobčar3; Laurent Pambaguian4; Marjetka Conradi1; aleksandra kocijan1; 1Institute of Metals and Technology; 2Balmar; 3Faculty for Mechanical Engineering, University of Ljubljana; 4ESA European Space Research and Technology Centre
    We investigated the feasibility of the hybrid additive manufacturing of the Iconel 718 alloy by laser powder-bed fusion (LPBF) and direct-energy deposition (DED). While LPBF can produce geometrically complex parts, DED can realise a large product. In this investigation we related the microstructure to the mechanical properties and a post-processing heat treatment. An intermetallic, brittle, Laves phase was formed in the DED part of the hybrid samples. However, after annealing and aging this phase dissolved and in some areas a delta phase formed, which with other imperfections is the reason that the parts failed. For a hybrid part with excellent properties, there must be good bonding between the LPBF and DED parts, while the DED process must be adapted to prevent δ-phase precipitation. This new technology has the potential to produce high-added-value metallic products for space applications, that benefit from the properties developed through hybrid AM.

J-20: Modelling and Analysis of Single-pass Laser Cladded High Speed Steel Considering Phase Transformation Effects: Ke Ren1; Yiming Rong1; Zhichao (Charlie) Li2; Gang Wang3; 1Harbin Institute of Technology; 2Deformation Control Technology, Inc.; 3Tsinghua University
    Coaxial powder feed laser cladding has been widely used in the surface modification and strengthening of large-scale metallic components, for it has some unique advantages, such as fast response speed and flexible deposition direction. As the deposition material, ASTM T15 high speed steel can greatly enhance the wear-resistance because of its high hardness (≥800HV) and excellent mechanical properties (σ0.15≥3000MPa). However, the thermophysical properties differences between deposition layers and substrate will result in large inner stress and hardness gradient. For investigating the effect of high laser energy input on the solid phase transformation, the phase transition kinetics model of T15 is established by using DANTE software. Finally, a three-dimensional numerical model for single-pass laser cladded high speed steel is developed to predict solid phase transformation, hardness, and inner stress. The model calculates the variations of stresses and hardness into the depth, which provide a reasonable agreement with experimental results.

J-21: Numerical Modeling of Non-equilibrium Partitioning in Copper-iron Binary Systems Manufactured by Direct Metal Deposition (DMD): Daniel Yin1; Amit Misra1; Jyoti Mazumder1; 1University of Michigan
    The DMD manufacturing process produces high cooling rates within a small melt pool and can lead to high amounts of solute trapping. Solute alloy atoms that would normally segregate out into equilibrium phases cannot do so because of limited diffusion time and may result in super-saturated solid solutions. In this work, we utilize a numerical model to calculate the degree of solute trapping, defined as non-equilibrium partitioning. This model is first tested for a theoretical case with overall composition fixed to 50Cu-50Fe at.% to see the influence of increasing solidification rates. We then simulate DMD for an equimolar Cu-Fe powder printed on mild steel substrate and calculate the non-equilibrium phase compositions. For a single deposited track, cooling rates are high enough to yield significant solute trapping throughout the deposited track. The degree of solute trapping is highest near the free surface with a gradient that correlates with the cooling rate.

J-22: Repair of High Hard Steel Using Similar Filler Material by a Solid-state Additive Manufacturing Approach: Troy Pierson1; 1The University of Alabama
    Additive Friction Stir-Deposition (AFS-D) provides a new path for additively repairing materials damaged in-service. In this work, simulated repair of a machined crack or defect in a plate of ARMOX 500T steel was performed across varying grooved morphologies and depths. Specifically, three different groove depths and three different sets of process parameters were correlated to the resulting deposition microstructure and mechanical properties. Macroscopically, side wall adhesion performed well on a V-shaped groove; however, in some of the process parameters and groove depths, poor mixing and porosity was observed at the base of the V-groove. Analysis of the phases and grain structure was performed using optical and electron microscopy techniques. Lastly, hardness mapping was preformed across the deposition cross-sections, and the hardness results show a decrease in hardness of the deposition compared to the substrate with a well-defined heat affected zone.