Additive Manufacturing of Large-scale Metallic Components: On-Demand 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

Monday 8:00 AM
March 14, 2022
Room: Additive Technologies
Location: On-Demand Poster Hall

Microstructure Control in Wire-arc Additively Manufactured Maraging Steels: Yukinori Yamamoto1; Peeyush Nandwana1; Andrzej Nycz1; Mark Noakes1; Ben Schaeffer2; Badri Narayanan2; 1Oak Ridge National Laboratory; 2Lincoln Electric
    Alloy design of maraging steels is highly matched with a nature of additive manufacturing technique since the major strengthening process relies on post-print heat treatments without thermomechanical treatments. Printing near-net shape components, followed by the strengthening heat-treatments, allows the production of large-scale metal components to be readily used for various applications, such as die-tools, after applying a limited amount of surface machining. The present study focused on wire-arc additively manufactured (WAAM) maraging 250/300/350 steels which applied standard and modified heat-treatments, targeting maximized hardness suitable for die-tool applications together with isotropic mechanical performance through controlling an equi-axed prior-austenite grain structure. Microstructural responses after various heat-treatments were corelated with the mechanical properties, and then utilized for optimization of heat-treatment suitable for the WAAM maraging steels. Research sponsored by the U.S. DOE, Office of EERE, Additive Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC, and supported by a collaboration with Lincoln Electric.

Reverse Engineering of Aerospace Components Utilizing Additive Manufacturing Technology: Balakrishnan Subeshan1; Abdulaziz Abdulaziz1; Zeeshan Khan1; Md. Uddin1; Muhammad Rahman1; Eylem Asmatulu1; 1Wichita State University
    Reverse engineering is a preferred solution for reproducing obsolete parts. Additive manufacturing made significant impact on the manufacturing industry throughout the world. There are various application fields where additive manufacturing can make significant impacts, and one of these fields is the aerospace industry. This study presents technologies and methodologies for reverse engineering, illustrated by a stainless steel lever part from an aircraft control assembly. It involves the reconstruction of part geometry using laser scanning, fabrication of the pattern for sand casting using material extrusion additive manufacturing technology, and reversed part fabrication using sand casting. It was found that the fabrication of patterns directly from reverse-engineered computer-aided design (CAD) data using a suitable additive manufacturing technique provides a reliable and economic path for rapid product development of complicated one-off parts for replacement purposes. The process of reverse engineering comprises laser scanning, CAD data, and manufacturing steps to make the part successful.