Additive Manufacturing: Materials Design and Alloy Development V – Design Fundamentals: Poster Session
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; Jiadong Gong, Questek Innovations LLC; Orlando Rios, University of Tennessee; Atieh Moridi, Cornell University
Monday 5:30 PM
March 20, 2023
Room: Exhibit Hall G
Location: SDCC
Development of Low-Mn added Fe Based Lightweight Steel via Direct Energy Deposition: Kwang Kyu Ko1; HyoJu Bae1; EunHye Park1; Hyokyung Sung1; Junggi Kim1; JaeBok Seol1; 1Gyeongsang National University
Recently, Research on a Layer-by-Layer process rather than the existing casting process is being actively conducted and applied to various industries such as automobiles. Due to environmental and energy efficiency issues, the automotive industry is focusing on reducing the weight of materials. However, the existing method of reducing the thickness has limitations such as decreased stiffness and vibration. In addition, the use of Al alloy, Mg alloy, etc. for weight reduction has a disadvantage of high price. By designing and establishing process conditions for low-Mn added Fe-based lightweight steel with Fe-Mn-Al-C composition, we overcome the high cost of existing alloys like high-Mn added or medium-Mn Fe based steels through the DED process, a representative metal additive manufacturing process. Additionally, we confirmed that the casting material and low-Mn added Fe-based lightweight steel have similar properties.
A-54: Enhanced Mechanical Properties of Functional Grade Materials Fabricated from 316L Stainless Steel and Fe-based Medium Entropy Alloy Using Direct Energy Deposition Process: Eun Seong Kim1; Gangaraju Manogna Karthik2; Soung Yeoul Ahn1; Sang Guk Jeong1; Yoon-Uk Heo1; Hyoung Seop Kim1; 1POSTECH; 2BITS Pilani
In this study, functionally graded material (FGM) of austenitic 316L Stainless Steel (STS) and iron based medium entropy alloy (MEA) in austenitic metastable phase were fabricated by direct energy deposition (DED). As a result of mechanical properties, the twin induced plasticity (TWIP) of STS and the transformation induced plasticity (TRIP) deformation behavior of MEA are shown to greatly delay the plastic instability and help in realizing materials with higher ductility. As a result, elongation was improved without compromising the strength.
A-55: Optimization of Directed Energy Deposition Processed Inconel 625 Alloy via Response Surface Methodology: Minseok Gwak1; Gideok Park2; Jae Bok Seol1; Hyokyung Sung1; Jung Gi Kim1; 1Gyeongsang National University; 2Doosan Heavy Industries & Construction
Although Inconel alloys are useful to build structural parts for turbine system, its maintenance is not convenient. So the replacing parts becomes popular strategy though it requires high cost and time. To overcome this problem, repairing technology through directed energy deposition (DED) is one of the attracting issues and many studies are being conducted. However, DED easily causes external defects such as voids and cracks, which result in the deterioration of the mechanical properties of the products. Hence, reducing external defects is essential, but the optimization strategy has not yet been clearly established due to the various processing parameters of DED. Therefore, the present study applies the response surface methodology (RSM) to control the defects and properties of Inconel 625 samples fabricated by DED. Based on the derived optimal conditions via RSM, we can obtain the optimal samples for evaluating their mechanical properties in various conditions.
Peculiarities of Structure Formation in Aluminum Alloys Alloyed with Transition Metals during Laser Powder Bed Fusion: Ivan Grushin1; Dmitriy Ryabov1; Igor Yadroytsev1; 1Light Materials and Technologies Institute UC RUSAL
Currently, in additive manufacturing, more and more attention is paid to the development of new materials, since materials are one of the key components of these advanced technologies. Without new materials, there are no new innovative products. Additive manufacturing provide a unique chance to develop materials, relatively speaking, in digital form, thereby making it possible to simultaneously design the material and design of the part, thus obtaining a single engineering object. In this paper, the features of structure formation in aluminum-based materials and their influence on properties in additive manufacturing are considered. The influence of alloying with transitional and refractory additives on the morphology of structural components, their kinetics and influence on physical and mechanical parameters is shown.
A-56: Synchrotron X-ray Imaging of the Effect of TiB2 Additions on Laser Powder Bed Fusion (LPBF) of Al-2139: David Rees1; Chu Lun Alex Leung1; Joe Elambasseril2; Sebastian Marussi1; Saurabh Shah1; Shashidhara Marathe3; Milan Brandt2; Mark Easton2; Peter Lee1; 1University College London; 2RMIT University; 3Diamond Light Source Ltd
Laser powder bed fusion (LBPF) of Al 2XXX series alloys is ideally suited for producing low volume specialist aerospace components. However, a high susceptibility to hot cracking reduces the mechanical performance and fatigue resistance of these parts due to the presence of cracks introduced during fabrication. We investigated two strategies to suppress the formation of hot cracks by controlling solidification behavior: 1) TiB2 inoculant additions; and 2) optimization of LPBF process parameters. Using high-speed synchrotron X-ray imaging, we monitored the LPBF of Al-2139 with and without the addition of TiB2 for a range of parameters. To quantify the resultant defect population, we also performed post-build synchrotron computed tomography. Our results show 3D quantification of defect morphology and the volume fraction of defects, revealing that inoculant addition give a reduction in crack volume of up to 79%, as well as reducing the average length, breadth and surface area of cracks.