Additive Manufacturing of Refractory Metallic Materials: Additive Manufacturing of Refractory Alloys and Hybrid Alloys and Components
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee, TMS: Refractory Metals & Materials Committee
Program Organizers: Antonio Ramirez, Ohio State University; Jeffrey Sowards, NASA Marshall Space Flight Center; Isabella Van Rooyen, Pacific Northwest National Laboratory; Omar Mireles, Los Alamos National Laboratory; Eric Lass, University of Tennessee-Knoxville; Faramarz Zarandi, RTX Corporation; Edward Herderick, NSL Analytical; Matthew Osborne, Global Advanced Metals
Tuesday 2:30 PM
March 1, 2022
Room: 262C
Location: Anaheim Convention Center
Session Chair: Omar Mireles , NASA MFSC; Edward Herderick, NSL Analytical; Faramarz Zarandi, RTX Corporation
2:30 PM Cancelled
Development of Titanium-steel Hybrid Material Using DED Additive Manufacturing Technology: Sung Chan Yoo1; Hyun-Gil Kim1; 1Korea Atomic Energy Research Institute
Titanium and titanium alloy have been known for their excellent properties, including high mechanical properties, low density, and high corrosion resistance, which attracted many interest from various industries, such as aerospace, automotive, defense, biomedical and nuclear. However, regardless of the natural abundance of titanium, the difficulties associated with processing of titanium have hindered wide-spread application of titanium in these fields. Herein, we have utilized the direct energy deposition (DED) method to design and manufacture hybrid composite materials consist of titanium/titanium alloys and stainless steel. The most important point in depositing the titanium on the surface of steel substrate is overcoming the large difference in thermal expansion coefficients of two materials. To solve this problem, the process conditions were optimized by controlling the heat accumulation on substrate and evaluating the macro/microstructure. By applying this method, we have developed titanium/titanium alloy-stainless steel hybrid material through the DED process.
2:50 PM
Union of Mo and Cr Alloys into a Single Multi-materials Part Using Laser-powder Directed Energy Deposition: Vincent Jacquier1; Julien Zollinger2; Frédéric Schuster3; Hicham Maskrot1; Philippe Zeller1; Wilfried Pacquentin1; 1Université Paris-Saclay, CEA, Service d'Etudes Analytiques et de Réactivité des Surfaces, 91191, Gif-sur-Yvette, France; 2IJL, Université de Lorraine, CNRS, 54000 Nancy, France; 3Cross-Cutting Program on Materials and Processes Skills, CEA, Université Paris-Saclay, 91191 Gif-sur-Yvette, France
We present the fabrication and analysis of a refractory Mo-Cr multi-layer gradient created by LP-DED (Laser-Powder Directed Energy Deposition) with a 1.2 mm wide laser spot. An inductive heating system allows the preheating of the substrate to increase the delivered energy and mitigate crack formation. Mo being more refractory than Cr the injection of Mo powders in a Cr-rich melt pool leads to a Mo-Cr interface containing partially dissolved Mo particles. With increasing power and Mo content in subsequent layers the complete fusion of Mo powder in Mo-rich melt pools is obtained. The high measured micro-hardness is attributed to solid solution strengthening combined with the fine micrometric equiaxed grains generated. Deposition of Mo on Cr is eased by the generation of a compositional gradient which leverages the complete solubility of these two metals to smooth the abrupt changes in properties and process parameters, thus avoiding the overheating of the initial Cr layer.
3:10 PM
Enhancement of the Thermal Conductivity of Inconel 718 with the Addition of Tungsten: Cory Groden1; Eric Nyberg1; Amit Bandyopadhyay1; 1Washington State University
Tungsten is a highly used material in additive manufacturing due to its high hardness, tensile strength, and impact resistance. In addition, the thermal conductivity of tungsten is high. In this project, Inconel 718 and tungsten bimetallic parts were printed using a directed energy deposition (DED) metal printer. The hypothesis was that the addition of tungsten layers would increase the thermal conductivity of the bimetallic. The thermal tests demonstrated an increase in thermal conductivity of the bimetallic than pure Inconel 718. The printed bimetallic showed no cracking at the interface or in the pure alloys when tungsten was printed on Inconel 718. Furthermore, a hardness profile was done at the interface of the bimetallic, which showed a smooth linear transition between the hardness of each of the pure alloys. This presentation will discuss the processing, microstructure, mechanical and thermal properties of Inconel 718 and tungsten bimetallic parts.
3:30 PM
Laser Assisted Cold Spray Deposition for Niobium and Tantalum Materials: Brett Roper1; Luke Brewer1; Paul Allison1; Andy Deal2; Tim Eastman2; 1The Univerisity of Alabama; 2Kansas City National Security Campus
This presentation will describe the first results on the application of in situ laser heating during the cold spray deposition of niobium and tantalum metal powders. High pressure cold spray is a solid-state deposition process in which powders are accelerated through a converging-diverging de Laval nozzle to supersonic velocities and then plastically deform upon impact with a substrate to create a fully dense deposition. In this research, we employ in situ laser heating to assist with deposition and to modify the deposition microstructure. The microstructure of the deposited materials is being characterized by optical and electron microscopy, with the use of electron backscatter diffraction, in particular. The presentation will describe changes in microstructure as a function of laser heating.This work was funded by the Department of Energy’s Kansas City National Security Campus which is operated and managed by Honeywell Federal Manufacturing Technologies, LLC under contract number DE-NA0002839.
3:50 PM Break
4:10 PM
Study of Melt-pool Geometry and Microstructure in Pure W by Powder-feed Directed Energy Deposition: Amaranth Karra1; Maarten de Boer1; Bryan Webler1; 1Carnegie Mellon University
This study examines melt pool geometry and microstructure of pure tungsten deposited by powder-feed directed energy deposition additive manufacturing. Single beads and pads of material were deposited on tungsten and steel base plates. A model predicting melt pool geometry, layer height, and bead composition as a function of powder, travel speed, and powder feed rate was developed and assessed by the experimental results. The microstructure and cracking of the tungsten beads and pads was also assessed and the behavior between different base plates was compared. Results showed how melt pool geometry predictions can guide process parameter selection and the effect of base plate and process parameters on build quality.