Additive Manufacturing and Innovative Powder/Wire Processing of Multifunctional Materials: Innovative AM Techniques and Feedstock Materials
Sponsored by: TMS Functional Materials Division, TMS Materials Processing and Manufacturing Division, TMS: Magnetic Materials Committee, TMS: Additive Manufacturing Committee, TMS: Powder Materials Committee
Program Organizers: Daniel Salazar, BCMaterials; Markus Chmielus, University of Pittsburgh; Emily Rinko, Honeywell Fm&T; Emma White, DECHEMA Forschungsinstitut; Kyle Johnson, Sandia National Laboratories; Andrew Kustas, Sandia National Laboratories; Iver Anderson, Iowa State University Ames Laboratory
Thursday 8:30 AM
March 23, 2023
Room: 23C
Location: SDCC
Session Chair: Kyle Johnson, Sandia National Laboratories
8:30 AM
Design of Complex Active Microstrustrures by Melt Electrowriting Printing with Functional Fillers: Paula Gonzalez1; Ander Reizabal1; Simon Luposchainsky1; Senentxu Lanceros-Mendez2; Paul Dalton1; 1Knight Campus; 2BCMaterials
The design of multifunctional materials with controlled micro-features is critical for many applications. To achieve high-resolution 3D printing, melt electrowriting (MEW) emerged as a novel electrohydrodynamic technique that allow to deposit polymeric microfibres in a very precise way. Despite its advantages, MEW is a young technology, so there are plenty of possibilities to be explored. In particular, the use of functional fillers within the MEW-processed structures to promote active properties remains so limited. This work explores the potentials of MEW for active materials printing by using different fillers. In particular, magnetic, conductive and color changing fillers are explored for develop sensors, actuators and conductive samples. Results demonstrate that different complex microstructures, including multi-material, with up to 6% wt. of fillers could be successfully printed without affecting to the printing quality and providing the printed structures with the desired active properties (magnetic response, actuation and/or sensing response).
8:50 AM
Accelerating Additive Manufacturing Process Design for Energy Conversion Materials using In-situ Sensing and Machine Learning: Joy Gockel1; Tanvi Banerjee2; Saniya LeBlanc3; Joe Walker4; Vijayabarathi Ponnambalam3; Amanuel Alambo2; Clayton Perbix1; Ankita Agarwal2; John Middendorf4; 1Colorado School of Mines; 2Wright State University; 3George Washington University; 4Open Additive
One promising candidate for manufacturing of the bismuth telluride thermoelectric legs is laser powder bed fusion (LPBF) additive manufacturing (AM). AM processing parameters highly influence the material properties, however current processing parameter development methods in AM are costly and time consuming. In-situ sensors allow for the capture of physically relevant process information on a layer-by-layer basis and will be used to aide process development. To optimize the AM process for the best thermoelectric performance, process variables, in-situ process sensor data and ex-situ material characterization data are collected. Several different interpretable machine learning (ML) approaches are used, and the performance of each method are assessed. Significant input process variables include laser focus, hatch spacing and laser power. The best performing models are used to determine the manufacturing parameters that maximize the power factor. AM of bismuth telluride material provides the ability to create complex geometries enabling more efficient energy conversion.
9:10 AM
Characterisation of Gas Atomized Micro-alloyed Nickel Silicide Powders for Additive Manufacturing: Ibrahim Mohammad1; Geir Grasmo1; Ragnhild Aune2; 1University of Agder; 2Norwegian University of Science and Technology
Nickel silicides are well known for their immense stability at high temperatures, as well as for being resistant to oxidation and corrosion in many thermal scenarios. In view of this, nickel silicides are ideal candidates for use in turbine blades and other underwater applications. A major concern regarding these materials has always been their low ductility making it difficult to manufacture large components. The presence of small quantities of Mo, Co, Ti, B and V has previously proven to increase the workability of silicides, and an attempt has therefore been made in this study to produce powders of micro-alloyed nickel silicides for Additive Manufacturing (AD) using gas atomisation. The overall microstructure, phase constitution, thermal properties, surface morphology, and density of the produced powders (NiSi11.9Co3.4, NiSi10.15V4.85, NiSi11.2Mo1.8, and NiSi10.78Ti1.84B0.1) have been evaluated using standard analytical techniques (SEM, EDS, XRD, DSC, XPS, pycnometry) to identify the alloy with optimum properties for AM.
9:30 AM
Engineered Platelets for Metals Additive Manufacturing: Vasiliki Poenitzsch1; Carl Popelar1; John Macha1; 1Southwest Research Institute
We are investigating engineered metal platelets produced by a vacuum roll coating process for establishing next generation forms of metal additive manufacturing source materials. Platelets are planar particles of uniform geometry and high aspect ratios. Some of potential advantages to vacuum roll coating engineered platelets include precisely controlled morphology (size and shape), increased packing density for the powder bed, ability to manufacture multilayer and/or coated particles, and tailorable material properties including surface textures and chemistries. In this development work, Selective Laser Melting Additive Manufacturing (SLM-AM) test builds were conducted from Ti-6Al-4V platelets made via a vacuum roll coating process. The material properties were characterized and compared against parts built with traditional Ti-6Al-4V powder.
9:50 AM
Embedding Hidden Information in Additively Manufactured Metals via Magnetic Property Grading for Traceability: Deniz Ebeperi1; Daniel Salas Mula1; Ibrahim Karaman1; Richard Malak1; Raymundo Arroyave1; 1Texas A&M University
Counterfeiting is a significant problem in global product market which has social and economic consequences, such as fiscal losses, failure of investments and unemployment. According to International Commission of Commerce in 2022, the total value of counterfeit products will reach $2.3 trillion, and their negative impact on global economy will be $4.2 trillion while putting 5.4 million employments at stake. We have recently developed a cost-effective countermeasure for counterfeiting, by embedding information as hidden magnetic barcodes via direct energy deposition of stainless steels with different magnetic properties. The local magnetic flux was measured in fabricated parts to obtain a magnetic flux intensity map, clearly revealing the embedded magnetic barcode. A comparison between microstructure of different stainless steels and magnetic flux intensities revealed the effects of process parameters on magnetic response. Optimization of processing parameters were discussed in the light of the challenges associated with incorporating this technique in practice.
10:10 AM Break
10:25 AM
High-Throughput Functional Materials Development with Miniaturized AM Coupons and Novel Characterization Techniques: Stefan Colton1; Aaron Stebner1; Brad Boyce2; 1Georgia Institute Of Technology; 2Sandia National Laboratories
Additive Manufacturing allows for the rapid and on-demand production of samples for materials development, but this throughput is often significantly limited by bottlenecks in characterization. While there has been significant research into high-throughput mechanical characterization, many functional properties still require tedious methods not optimized for AM. In this work, novel methodologies for characterizing functional properties are developed, alongside corresponding miniaturized AM samples: optical dilatometry is adapted to rapidly measure the anisotropic thermal expansivity of AM samples; soft magnetic properties are estimated from the reaction of AM samples in graded magnetic fields. These techniques are then used to explore a large feature space of Fe-Ni alloys printed by Directed-Energy Deposition, and their accuracy and throughput evaluated. It is shown how these techniques enable a Sequential Learning framework, where they can be used for screening and exploration and paired with lower throughput but more accurate methods.
10:45 AM
Investigation Towards Adaptation of Wire-Powder Laser Directed Energy Deposition Process to Optimized Simulation: Stephanie Lawson1; Sriram Manoharan1; Somayeh Pasebani1; Brian Paul1; Ali Tabei1; 1Oregon State University
Within laser directed energy deposition (LDED) process, research has expanded into using a combination wire-powder feed to combine multiple materials within the process to produce materials with enhanced properties. The objective of this study was to reconstruct a complex wire-powder LDED process for numerical simulation. Deconstruction of the process and calibration of each component was executed to uncover the closest approximation and optimization for conversion from equipment setup to model. Laser parameters coupled with wire angle conversion were shown to contribute to significant output variations, while powder feed settings had little effect on output measurements. Although one specific process setup was investigated, the simulation demonstrates that a six-laser, three-powder feed, single wire process can be simulated using a single laser, two-powder feed, single wire configuration. By exploring the approach to simulate the wire-powder LDED process, we evaluate the ability to produce bimetals using two material feedstocks in a LDED process.
11:05 AM
Manufacturing of Oxide Dispersed Nickel Base Alloy by Laser Powder Bed Fusion from Powders Elaborated by Different Processes: Cécile Blanc1; Olivier Hercher1; Jérôme Varlet1; Fernando Lomello1; Hicham Maskrot1; Pascal Aubry1; 1CEA Paris-Saclay
Laser Powder Bed Fusion (LPBF) allows innovative design with complex geometries and offer new perspectives to develop new alloys with tailored the functional properties. Recent publications reports that addition of oxides to generate nano-dispersed particles into the base material can increase its mechanical, irradiation and corrosion properties. Therefore, this article proposes to study in the influence of Y2O3 addition on the microstructure of additively manufactured Inconel 718. Processes such as mechanical mixing and Physical Vapor Deposition have been evaluated to integrate nanometric oxide particles in the base material. However, the addition of oxide requires an adaptation of the LPBF process parameters. Main parameters as process speed, laser power, hatching distance, and scanning strategies are considered for each oxide insertion process. Finally, macro and microstructures are analyzed and conclusion are given on the potentialities and limitations of each manufacturing condition and type of nanometric integration process.
11:25 AM
Spatially Resolving Structure-Behavior Relations in Laser Directed Energy Deposition Based Additive Manufactured Adaptive Materials: Arnab Chatterjee1; Reginald Hamilton1; 1Penn State
Shape Memory Alloys (SMAs) are a class of adaptive materials that undergo solid state crystallographic phase change with the application of stress or temperature. The underlying MT is reversible and enables SMAs to recover exceptionally large bulk-scale shape change, compared to conventional elastic recovery. In this work, we fabricated Nickel-Titanium based SMAs using the now well-known advanced fabrication method, additive manufacturing (AM). The layer-by-layer manufacturing customizes extrinsic geometrical shapes, dimensional scales and intrinsic composition-structure. We employ the Laser Directed Energy Deposition (LDED) AM technique using pre-blended elemental powder feedstock for depositing Titanium-rich NiTi SMAs. Because of layer/pass wise buildup, the intrinsic structural scales will vary spatially. We spatially resolve structure-behavior relations using a combined study of X-Ray and electron diffraction, optical microscopy, and microhardness. Signatures of layer/pass wise build are revealed and we produce spatial maps for contrasting the degree heterogeneity of differential LDED AM build plans.
11:45 AM
Ultrasonic Powder Atomisation for R&D - Inventors Perspective: Lukasz Zrodowski1; 1Amazemet
Ultrasonic atomization is one of the least studied and known processes used for manufacturing metallic powders. The newly developed induction and plasma-based ultrasonic systems allow to speed up the research and introduction of new materials for Additive Manufacturing. The technology involves ultrasonically agitated sonotrodes that allow the spraying of molten alloys with tailored chemical composition.Examples of ultrasonic atomization for pulverization of multiple R&D systems from light alloys such as Mg-Li up to refractory High Entropy Alloys such as WtaVTi have been shown. The manufactured powder is characterized by high quality in terms of contamination, narrow particle size distribution which can be controlled by the frequency of ultrasonic vibrations, lack of satellites, and exceptional sphericity. Additionally, use of ultrasonic atomization for Zr-based alloys screening has been shown.