Additive Manufacturing: Materials Design and Alloy Development III -- Super Materials and Extreme Environments: Fundamentals
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
Monday 8:30 AM
March 15, 2021
Room: RM 3
Location: TMS2021 Virtual
Session Chair: Behrang Poorganji, Beehive3D; James Saal, Citrine Informatics
8:30 AM
Introductory Comments: Additive Manufacturing: Materials Design and Alloy Development III -- Super Materials and Extreme Environments: Behrang Poorganji1; 1University of Waterloo
Introductory Comments
8:35 AM Invited
AM Enabled Super Materials for Extreme Environments Applications: Youping Gao1; John Porter1; Cameron Schmidt1; 1Castheon Inc
Refractory alloys have extraordinary resistance to heat, wear, and with superior durability, often the desired material for extreme environment applications for space craft, missiles, and hypersonic vehicles. Their high cost of manufacturing into complex shapes have impeded their application in the most demanding environment. Additive manufacturing has demonstrated superior shape producing capability that could not be possibly produced with conventional manufacturing processes. The AM also thrust the refractory alloys into much higher performance materials comparing to its wrought equivalent. With integrated engineering functions such as heat pipes for effective thermal management, catalyst beds for efficient thrust control, the integrated AM enabled 3D printed refractory structures have permitted spacecraft higher performance in the extreme application environments. In this presentation, progress in achieving high quality and high performance refractory components by additive manufacturing are reported. Case studies of performance gain in sophisticated engineering hardware will also be presented.
9:05 AM Invited
Development of a Rapid Alloy Selection Tool for Rapid Solidification Processing Conditions: Emma White1; Ralph Napolitano1; Timothy Prost1; Duane Johnson1; Samantha Tatar2; Naren Raghavan3; Michael Kirka3; Andrew Kustas4; Nicolas Argibay4; Iver Anderson1; 1Ames Laboratory; 2Kansas City National Security Campus; 3Oak Ridge National Laboratory; 4Sandia National Laboratories
Additive manufacturing (AM) requires new alloys to take advantage of this new processing space – localized heating, small volume melting, rapid solidification, repeat melting, etc. Currently used alloys were developed for cast, wrought or powder metallurgy applications and frequently show defects when processed by AM, for example build cracking of high γ’ Ni-based superalloys. To expedite alloy design and selection, a new approach has been developed that incorporates property targets with thermodynamic and electronic structure modeling with a rapid solidification analysis set of tools, including microstructure and properties, followed by powder production and AM build validation. The results of the approach across three different alloy families – high strength Al alloys, Ni-based superalloys and multi-principle element alloys – will be described with the implications for shortening turnaround time for exploring new compositions from years to just months and accelerating the adoption of AM. Funding from DOE-EERE-AMO through DE-AC02-07CH11358.
9:35 AM
Additive Manufacturing and Characterization of High-density Materials for Aerospace Applications: Kristyn Kadala1; Scott Smith1; 1Lockheed Martin ATC
Refractory and high Z materials are essential for aerospace applications and environments demanding high thermal and structural loads. These materials are difficult to machine due to embrittlement, hardness, and toughness and are primarily cast or wrought due to high melting temperatures. As a result, manufacturing costs are often extremely high. To mitigate manufacturing and production risk, additive manufacturing of high Z materials through laser powder bed fusion presents a challenging yet attractive production solution by reducing touch labor, reducing production material waste, and allowing for more complex geometries than traditional machining. However, many AM parts are prone to cracking and embrittlement due to high rate of oxidation and thermal stresses experienced during a print. Our exploration into refractory and high Z alloy powders aims to mitigate micro-cracking risks while providing the same material properties valued so highly in the aerospace industry for traditionally machined refractory metal parts.
9:55 AM Invited
Computational Design and Additive Manufacturing-Enabled Fabrication of Functionally Graded Steel-to-Tungsten Joints for Fusion Energy Applications: Dana Frankel1; Marie Thomas1; Pin Lu1; Olga Eliseeva2; Tanner Kirk2; Raymundo Arroyave2; Ibrahim Karaman2; 1QuesTek Innovations LLC; 2Texas A&M University
To enable advanced fusion energy technology, next-generation cooling systems for tokomak fusion reactors will utilize cooling system designs that require joining of tungsten-based plasma-facing armor to steel cooling structures. Conventional joining techniques result in substantial mismatch of thermal properties which can lead to cracking along the joint interface during operational cycles. Grading of the joint reduces thermal stresses, but linear steel-to-tungsten gradients can result formation of undesirable brittle phases. Computational design of an appropriate composition pathway is required to avoid brittle phases and optimize properties to create a robust joint. A computational path planning framework allows for optimization of properties through complex multidimensional composition space. A unique steel-to-tungsten gradient was designed using computational thermodynamic modeling tools and fabricated using directed energy deposition (DED)-based additive manufacturing (AM). Analysis indicates that the graded samples remain free of detrimental phases and thermally-induced cracking after extended cyclic testing.
10:25 AM Invited
Rapid Exploration of Refractory Complex Concentrated Alloys via Additive Manufacturing and Molecular Dynamics: Andrew Kustas1; Jonathan Pegues1; Michael Melia1; Raymond Puckett1; Shaun Whetten1; Morgan Jones1; Nicolas Argibay1; Michael Chandross1; 1Sandia National Laboratories
Refractory Complex Concentrated Alloys (RCCAs), typically consisting of four or more elements in high concentration, are a class of materials that often possess remarkable structure-properties relationships. However, it is challenging to efficiently explore the multidimensional phase and composition space of these materials with conventional manufacturing routes. This talk presents recent efforts in implementing a high throughput alloy processing methodology to rapidly assess RCCA structure-properties relationships via metal Additive Manufacturing (AM). The methodology is outlined and select case studies are presented to illustrate the efficacy of the approach. High throughput Molecular Dynamics simulations that provide rapid insight into material properties predictions are also presented. Preliminary results demonstrate the value proposition of utilizing high throughput experimental processing and computational tools to accelerate materials development for AM. SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525
10:55 AM
Application of Taguchi, Response Surface, and Artificial Neural Networks for Rapid Optimization of Laser-based Powder-Bed Fusion Process: Ebrahim Asadi1; Behzad Fotovvati1; Faridreza Attarzadeh1; 1University of Memphis
Laser-based powder-bed fusion (L-PBF) is a widely used additive manufacturing technology that contains several variables (processing parameters), that makes it challenging to correlate them with the desired properties (responses) when optimizing the responses. In this study, the influence of the five most influential L-PBF processing parameters of Ti-6Al-4V and WE43 alloys—laser power, scanning speed, hatch spacing, layer thickness, and stripe width—on the relative density, microhardness, and and roughness parameters are thoroughly investigated. Two design of experiment (DoE) methods, including Taguchi L25 orthogonal arrays and fractional factorial DoE for the response surface method (RSM), are employed. A multiobjective RSM model is developed to optimize the L-PBF processing parameters considering all the responses with equal weights. Furthermore, an artificial neural network (ANN) model is designed and trained based on the samples used for the Taguchi method and validated based on the samples used for the RSM.