Additive Manufacturing for Energy Applications V: Processes and Optimization I
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS Structural Materials Division, TMS: Additive Manufacturing Committee, TMS: Nuclear Materials Committee
Program Organizers: Isabella Van Rooyen, Pacific Northwest National Laboratory; Subhashish Meher, Pacific Northwest National Laboratory; Xiaoyuan Lou, Purdue University; Kumar Sridharan, University of Wisconsin-Madison; Michael Kirka, Oak Ridge National Laboratory; Yi Xie, Purdue University
Thursday 8:30 AM
March 23, 2023
Room: 23A
Location: SDCC
Session Chair: Xiaoyuan Lou, Purdue University
8:30 AM Introductory Comments
8:35 AM Invited
Compositionally Graded Alloys Fabricated by Laser Powder Bed Fusion: Siyuan Wei1; Pei Wang2; Baicheng Zhang3; Ramamurty Upadrasta1; 1Nanyang Technological University; 2Institute for Materials Research; 3USTB
The ability of some additive manufacturing techniques such as laser powder bed fusion (LB-PBF) for alloying in situ allows for the fabrication of compositionally graded alloy (CGA) coupons which can be utilized for fast screening of potential new alloys and/or fabrication of functionally graded engineering components. Towards these ends, we have explored several different CGAs that are fabricated using LB-PBF with variations in the powder supply mechanisms, gradient direction (with respect to the build direction), and the degree of powder mixing. Resulting microstructural evolutions and the chemically heterogenous mesostructures, and the effects of them on the mechanical properties of the fabricated parts are investigated. I shall discuss these results and surprising findings in this talk.
9:10 AM
DED Additively Manufactured HEAs Optimized via Parametric Study of Functionally Graded Materials: Calvin Downey1; Luis Nuņez1; Jakub Toman1; Mohammad Abdo1; Isabella van Rooyen2; 1Idaho National Laboratory; 2Pacific Northwest National Laboratory
The nuclear industry requires advanced materials that possess mechanical strength, corrosion resistance, and irradiation resistance. High entropy alloys (HEAs) such as FeCoCrNi perform well in these categories and can present a single phase (SP) FCC structure, seen to demonstrate superior irradiation resistance compared to multi-phase and BCC structures. Past investigations of HEAs revealed significant challenges in manufacturing the SP structures with conventional casting methods. Additive manufacturing (AM) presents novel HEA fabrication technologies such as laser-engineered-net-shaping (LENS). Process control in LENS, such as laser heat input and in-situ compositional control, make this method unique to overcome issues with conventional HEA manufacturing. This study investigates LENS fabricated compositionally functionally graded materials (FGM). FGM samples are produced for compositional phase control along with parametric studies of FeCoCrNi HEA-like structures. Electron backscatter diffraction mapping, microscopy, energy dispersive x-ray spectroscopy, and microhardness tests will determine microstructure, elemental distribution, and preliminary mechanical behavior.
9:30 AM
Production of ZrB2 Doped Inconel 718 Composite via Laser Powder Bed Fusion Method: Emre Tekoglu1; Alexander O'Brien1; Jian Liu2; Wen Chen2; John Hart1; Ju Li1; 1Massachusetts Institute of Technology; 2University of Massachusetts Amherst
Additively manufactured Inconel 718 is an important superalloy, which is used in aviation and nuclear industries owing to its superior mechanical stability and corrosion resistance at elevated temperatures. However, the related industries are looking for new material groups including of Ni-based metal matrix composites (Ni-MMCs) with better thermomechanical properties than their conventional counterparts. It is challenging to produce Ni-MMCs by conventional casting since the fine ceramic reinforcing NPs could not be uniformly distributed in the microstructure, leading to poor mechanical properties.Therefore, there has been a growing interest in the development of Ni-MMCs via additive manufacturing.On the other hand, ZrB2 is a transition diboride such as a frequently used reinforcing particle TiB2 but with a 300 ◦C higher melting temperature (Tm: 3246 ◦C).Within this context, we produced ZrB2 particle reinforced Inconel 718 MMC’s via laser powder bed fusion (LPBF) and compared their microstructural and tensile properties with the unreinforced In718 ones.
9:50 AM
Optimization of Laser-wire Direct Energy Deposition (LW-DED) of Superalloy Haynes 282: Rui Feng1; Kristin Tippey1; Chantal Sudbrack1; 1National Energy Technology Laboratory
Additive manufacturing (AM) using wire feedstock is an attractive lower-cost alternative to powder-bed techniques due to less material scrap. Nickel-based superalloy Haynes 282 has applicability to high-temperature components in the energy sector and is suitable for a wide range of AM techniques due to its weldability. However, achieving an optimized processing window for LW-DED Haynes 282 superalloys requires a systematic investigation of printing parameters, such as printing energy, speed, and hatch offset. Here we screen out an optimized printing window for LW-DED with the Meltio 450 platform on the Haynes 282 superalloy through studying the effects of these printing parameters on the printing quality, microstructures, and mechanical properties. The established understanding of the printing strategy-quality-microstructure-property relationship provides valuable insights into obtaining high-quality LW-DED Haynes 282 for future practical applications. This work is supported by NETL-FWP-1022406 Advanced Alloy Development.
10:10 AM Break
10:25 AM
CALPHAD-based Design of Graded Transition Joints: Peeyush Nandwana1; Rangasayee Kannan1; Thomas Feldhausen1; Kyle Saleeby1; Yousub Lee1; Andres Rossy1; Christopher Fancher1; Brian Jordan1; 1Oak Ridge National Laboratory
Austenitic and ferritic steels are two critical classes of steels with unique properties and costs that make them suitable for niche applications. As the energy sector pushes for higher efficiency and focuses on a hydrogen-based economy, it is imperative that these two steels will need to be joined to satisfy the varied requirements within a complex component. The difference in the coefficient of thermal expansion (CTE) and carbon chemical potential between the two steels often results in early failure at the joint. Here, we demonstrate the use of CALPHAD calculations to design a graded transition joint between Grade 91 steel and 347H stainless steel. The graded transition joint was fabricated using blown powder directed energy deposition and characterized. We show that the non-linear composition change in the transition zone results in a lower stress and carbon chemical potential compared to a linear transition joint.
10:45 AM
Combining Additive Manufacturing Processes to Produce Functionally Graded Metallic Materials for Energy Applications: Christopher Bettencourt1; Hailei Wang1; Nadia Kouraytem1; 1Engineering Utah State
One hurdle preventing wider implementation of Concentrated Solar Power is component cost. Heat exchangers are a large fraction of that cost, stemming from the requirement of high-temperature materials to withstand extreme conditions. However, by replacing the material at the low-temperature side of the heat exchanger with a lower cost material, the recuperator continues to perform adequately while minimizing the overall cost. This work suggests a novel combination of Laser Powder Bed Fusion and Directed Energy Deposition Additive Manufacturing. IN625 is deposited onto SS316L to provide functionally graded material (FGM) samples for mechanical and microstructural characterization. Two types of transitions are made between the alloys, namely, a direct transition and a 50/50 mixture of both alloys. Tensile properties of the FGMs are compared to both additively manufactured and wrought manufactured monotonic alloys. Scanning Electron Microscopy, Electron Backscatter Diffraction, and porosity analysis (through Computed Tomography scanning) are also conducted.
11:05 AM
Additive Manufacturing of Inconel 718 + SiC with Enhanced Tensile Strength and Uniform Ductility: Alexander O'Brien1; Emre Tekoglu1; Anastasios Hart1; Wen Chen2; Ju Li1; 1Massachusetts Institute of Technology; 2University of Massachusetts Amherst
We report the additive manufacturing of a nickel superalloy metallic matrix composite (Ni-MMC) using Selective Laser Melting. Inconel 718 with 2 vol% SiC nanowires were prepared by ball milling of nanowires and base alloy powder, which was found to produce a homogeneous distribution of SiC on Inconel surfaces. Analysis revealed dissolution of nanowires during laser powder bed fusion, leading to in-situ formation of Nb and Ti-based silicide and carbide nanoparticles. The SiC dissolution and resulting nanoparticles were observed to improve the material microstructure, reducing cracks/pores and decreasing average grain size after printing. Mechanical characterization of the printed Ni-MMCs after standard heat-treatment revealed notable increases in the hardness, ultimate tensile strength, and uniform tensile ductility. We believe this presents a simple and effective method for improving the usability of high-temperature materials prepared by additive manufacturing that may prove important in the face of ever-harshening environments in energy and propulsion applications.
11:25 AM
Nanoparticle-based Additive Manufacturing of Soft Magnetic Composites: Mingqi Shuai1; Luis Delfin1; Maryam Kazembeyki1; Melody Wang1; Wendy Gu1; 1Stanford University Mechanical Engineering Labs (Gu Group)
Soft magnetic composites (SMCs) are widely used as magnetic cores in power generation and electric motors. However, traditional manufacturing techniques, such as the press-and-sinter process, are time consuming, expensive, and limited by complex shape designs. Additive manufacturing (AM) provides more design flexibility and requires minimal end finishing. We have developed ‘NanoSLS’, a slurry-based additive manufacturing process in which a slot-die coating system is incorporated into a laser powder bed fusion (L-PBF) machine for the deposition of nanosized particles. A custom SMC ink that contains amorphous core-oxide shell nanoparticles is used to achieve better magnetic and mechanical properties. Rheology tests are conducted to determine the optimal coating window for the SMC ink in the slot-die. On top of the benefits offered by L-PBF AM processes, the NanoSLS process requires less feedstock material, generates less waste, is easier to operate and easy to scale up for mass production.
11:45 AM
Sintering Process Optimization for FeCrAl Alloys in Metal Extrusion Additive Manufacturing: Amrita Lall1; Saumyadeep Jana1; Zachary Kennedy1; Michelle Fenn1; 1Pacific Northwest National Laboratory
Iron-chromium-aluminum (FeCrAl) alloys are heat-resistant ferritic stainless-steels used in several high-temperature applications because of their high-temperature strength and form-stability. It forms a highly protective aluminum oxide layer, which provides high corrosion and oxidation-resistance. Metal extrusion additive manufacturing (MEAM) of FeCrAl alloy allows efficient manufacturing of complex designs. In this study, gas-atomized FeCrAl powder, consisting of 19-23.5% Cr, 4.5-5.5% Al, by wt.%, was used to produce FeCrAl/polymeric-binder composite pellets by adding binders and sintering them by varying hold time, ramp rate, temperature, and environment. Dilatometer tests and furnace sintering trials were conducted at temperatures upto 1400C, by adding isothermal holds at various temperatures for upto 24 hours in various environments. Optimization of sintering parameters resulted in thermal-debinding without delamination of adjoining layers and attainment of 99% density by volume. The analysis of resulting microstructure using optical and SEM/EBSD imaging revealed that the strengthening nano-sized oxide particle in the matrix are preserved.