Additive Manufacturing: Length-Scale Phenomena in Mechanical Response: Poster Session
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Nanomechanical Materials Behavior Committee
Program Organizers: Meysam Haghshenas, University of Toledo; Andrew Birnbaum, Us Naval Research Laboratory; Robert Lancaster, Swansea University; Xinghang Zhang, Purdue University; Aeriel Leonard
Monday 5:30 PM
March 20, 2023
Room: Exhibit Hall G
Location: SDCC
Session Chair: Meysam Haghshenas, University of Toledo
A-43: Additively Manufactured Structured Fabrics for Deployable Antenna Structures: Punnathat Bordeenithikasem1; Tracy Lu2; Connor McMahan2; Chiara Daraio2; 1NASA Jet Propulsion Laboratory; 2California Institute of Technology
Structured fabrics are continuums of interacting elementary particles or unit cells (e.g. chainmail is made of interlocking links). Such fabrics are conformable in the relaxed state, but become rigidized when the particles interlock/jam in response to an internal tension constraint. In this talk, we will discuss the development of a deployable reflector antenna for use in small satellites for Earth science investigations. The deployable structure will consist of hollow beads fabricated using additive manufacturing (AM). Wires will be threaded through the printed beads such that when the wires are tensioned beyond a threshold, the beads will jam into a rigid state, and deploy.
A-42: A Comparative Study of Microstructure and Multiscale Mechanical Properties of Additively Manufactured Near-α, α+β and β Titanium Alloys: Zhiying Liu1; Yu Zou1; Jiahui Zhang1; 1University of Toronto
Additively manufactured near-α, α+β and β titanium alloys have been applied in different scenarios of aerospace and automotive industries. However, a thorough comparison of microstructure and multiscale mechanical properties of different titanium alloys is not studied yet. Here, we use high-speed nanoindentation mapping tests coupled with electron backscattered diffraction (EBSD) to characterize the microscale mechanical properties and microstructure of three titanium alloys: Ti-6Al-2Zr-Mo-V (near-α), Ti-6.5Al-3.5Mo-1.5Zr-0.3Si (α+β) and Ti-10V-2Fe-3Al (β). All the alloys consist of α+β microstructure but exhibit variations in microstructure (grain size, morphology, and volume fraction) and microscale mechanical properties (H and E values). The H and E values of α grains vary in and between the titanium alloys due to the different crystal orientations and chemical compositions, respectively. The contribution of the microstructure and phase properties to macroscale mechanical properties of titanium alloys is also accessed to study the multiscale mechanical properties of additively manufactured titanium alloys.
A-44: Correlation between Strengthening Mechanism and Dislocation Characteristics of Selective Laser Melted H13 Hot Work Tool Steel: Sung-Ho Kim1; Yeonggeun Cho1; Sung-Joon Kim1; 1Graduate Institute of Ferrous & Energy Materials Technology(GIFT), POSTECH
Recently, additive manufacturing of H13 hot work tool steel has been spotlighted due to its high mechanical properties and tempering resistance while achieving lower tolerances compared to commercial grade H13. To find out the strengthening mechanism of the additively manufactured H13, the dislocation density was calculated using X-ray diffraction and EBSD, and the yield strength was calculated based on measured dislocation density. It was found that the calculated yield stress follows the experimentally measured values well, and confirmed that the high yield stress of the additively manufactured H13 was due to the high dislocation density compared to commercial grade H13. Furthermore, hardness-based indentation size effect (ISE) was analyzed to quantify the dislocation component of additively manufactured and commercial grade H13. As the indentation depth decreased, the GND density increased in additively manufactured H13. This is due to the GND at the cell boundary formed during solidification.
Development of a MATLAB Script to Analyze cb, a New Constitutive Mechanical Property Parameter: Ryan Holdsworth1; Benjamin MacDonald2; Enrique Lavernia2; Diran Apelian2; Alan Jankowski1; Joshua Yee1; 1Sandia National Laboratories; 2University of California, Irvine
Recently, a new application of a constitutive mechanical property parameter cb has been developed and demonstrated to effectively characterize critical mechanical properties in additively manufactured stainless steels (particularly 304L and 316L). A MATLAB script was developed to automate calculation and analysis of cb from load/displacement data. In this presentation, we discuss the development of the MATLAB script for analysis and show its robustness in handling large quantities of data sets. We also discuss opportunities for further development, including potentially leveraging machine learning.
Effect of Short Cycle Heat Treatment on the Microstructure and Mechanical Properties of Additively Manufactured Mar-M 509: Siba Sundar Sahoo1; Balila Nagamani Jaya1; Dheepa Srinivasan2; 1Indian Institute of Technology Bombay; 2Pratt & Whitney Research and Development Center
Mar-M 509 is a Cobalt based superalloy exhibiting excellent oxidation and hot-corrosion resistance, suitable for elevated temperature applications (nozzle guide vanes, blades) in aero-engines. Additive manufacturing of Mar-M 509 can produce end-use components with complex geometries, while maintaining dimensional tolerance even while achieving rapid cooling. Short-cycle aging heat treatment of laser powder-bed-fusion processed Mar-M 509 is explored in this study to enhance the mechanical properties of this alloy, especially tensile ductility, toughness, and fracture toughness while retaining room and elevated-temperature strengths. Detailed microstructural analysis across length scales (mm to nm) carried out using advanced characterization tools is correlated to novel miniature (mm), small scale, non-conventional, tensile and fracture toughness measurements combined with digital image correlation based in-situ strain mapping. Measurements are made across the longitudinal and transverse directions, before and after heat treatment. Micro-mechanisms leading to intrinsic and extrinsic size-effects based improvements in mechanical properties will be discussed.
A-45: Green Geopolymer Materials for 3D printing of Built Environment- Numerical Modelling and Experimental Validation: Shoukat Alim Khan1; Huseyin Ilcan2; Oguzhan Sahin3; Mustafa Sahmaran2; Muammer Koc1; 1Division of Sustainable Development, College of Science and Engineering, Hamad Bin Khalifa University, Qatar Foundation, Doha, Qatar; 2Department of Civil Engineering, Hacettepe University, Beytepe, Ankara, Turkey; 3Ankara University, Engineering Faculty, Civil Engineering Department
3D concrete printing (3DCP) is a key focus of digitalization in the construction industry, with the abilities of better-quality control, lower cost, construction time, and un-paralleled aesthetic, under the "construction 4.0". The significance of predicting the ultimate mechanical performance of the produced structure increases, as we get to more advanced, valuable, and larger-scale applications of 3DCP. The objective of this study is to analyze fresh material’s properties for the newly developed green geopolymer materials for the development of numerical and simulation models. Unconfined material testing and tri-axial compressive testing have been performed for Elastic modulus, Poisson ratio, Cohesion coefficient, friction angle and density calculation. The study also performs a comparative analysis of the developed numerical model and simulation with the experimental study for different geometrical and printing parameters. Based on the analysis of the results, different new printing strategies have been proposed to increase the overall performance of the process.
A-46: Investigation and Optimization of Compressive Mechanical Properties of Additive Manufactured TPMS-type Interpenetrating Phase Composites: Wei-Hsuan Liao1; Cheng-Che Tung1; Po-Yu Chen1; 1National Tsing Hua University
Triply periodic minimal surfaces (TPMS) structures widely found in nature possess superior properties and functionalities. Inspired by TPMS structures, novel interpenetrating phase composites (IPCs) are designed and fabricated from a wide range of materials. In this study, we investigate experimentally and computationally the compressive behavior of 3D-architectured two-phase IPCs and utilize TPMS structures as the second-phase reinforcements to enhance mechanical performances. To clarify the structure-property relations of the TPMS IPCs, systematic parametric studies on different relative densities, rigidities of solid constituents, and different types of TPMS are conducted. By applying 3D printing, multi-structural observations, and finite element simulation, compressive mechanical properties and stress distribution of Gyroid, Diamond, FRD, FKS, and IWP IPCs are evaluated and discussed. With the analytical results, the most effective TPMS IPCs in enhancing damage tolerance and mechanical performance have been determined, which have great potential to be applied in the defense, aerospace, automotive, and engineering fields.
A-47: Liquation Cracking Study of Additively Manufactured Alloy 718 Using Thermal-mechanical Simulator: Sangguk Jeong1; Gangaraju Manogna Karthik1; Soung Yeoul Ahn1; Eun Seong Kim1; Hyoung Seop Kim1; 1POSTECH
Additively manufactured alloy 718 has a very unique microstructure, which is distinguishable from wrought and cast alloy. In addition, the hot isostatic press (HIP), which is excellent for reducing internal defects and improving material properties, affects the microstructure a lot. On the other hand, in alloy 718, liquation cracking can occur due to the Laves phase and carbide. In this study, the liquation cracking behavior of additively manufactured samples was compared under three different heat treatment conditions (① As-built, ② stress relieved, and ③ HIPed).Using Gleeble 3500 thermal-mechanical simulator, NDT (nil ductility temperature) and DRT (ductility recovery temperature) were compared. Among the 3 conditions, HIP sample showed low DRT. In the HIPed sample, coarsening of grain size and Laves phase particle can be seen. It was confirmed that the decrease of the grain boundary length and the growth of the Nb-rich phase made the material susceptible to liquation cracking.
A-48: Mechanical Behavior of Additively Manufactured GRCop-84 Copper Alloy Lattice Structures: Daniel June1; Behzad Babamiri2; Kavan Hazeli1; 1The University of Arizona; 2The University of Alabama in Huntsville
This study investigates the relationship between microstructure, topology, and their combined effect on the quasi-static and dynamic behavior of additively manufactured Copper-Chromium-Niobium (GrCop-84) lattice structures. To determine whether topology was the only driving mechanism influencing mechanical properties e.g., yield strength, the as-built (AB) microstructure was altered through hot isostatic pressing (HIP) heat treatment while the sample topology was kept constant. Quasi-static and dynamic compression data showed the deformation process is independent of the relative density. It was found irrespective of the topology and unit cell size the post yielding of the AB samples was followed by a sudden load drop that coincides with either structural shear band formation or local instability causing sudden layer collapse. We also discuss how deformation mechanisms switch between structural shear band formation to layer-by-layer collapse triggered by strain localization depending on microstructure. The dependency of shear band formation on unit cell size is also discussed.
A-49: Microstructural and Mechanical Property Response to Build Parameters and Material Property Suite Development of Laser Powder Bed Fusion NASA HR-1: Madelyne Rushing1; Ryan Anderson1; Stephen Cooke1; Joseph Sims1; Melissa Forton1; 1Quadrus Corporation - Advanced Manufacturing
NASA HR-1 was developed to expand the field of high-strength, hydrogen resistant alloys available to the aerospace community. Quadrus Advanced Manufacturing (QAM) developed three different laser powder bed fusion (L-PBF) additive manufacturing (AM) build parameters for this alloy. QAM explored the effect parameters developed at 135W, 150W, and 180W on both the microstructural and mechanical behavior of the material. QAM prepared metallographic specimens and performed uniaxial tension testing with specimens built in the X-Y build plane and the Z-build direction to decide which of the three parameter sets should be used for the preliminary Qualified Metallurgical Process (QMP). All three parameters displayed equiaxed grain structures and impressive mechanical properties, but one resulted in a more refined microstructure than the others. QAM then created 18 metallographic specimens and 100 tensile specimens to develop a preliminary QMP for HR-1. Resulting in a sufficiently baselined material property suite.
A-50: Microstructure and Deformation Behavior of Microstructurally Manipulated Multi-phase Laser Powder Bed Fusion 3D-printed Novel Low Nickel Steels: Jan Capek1; Ashiah Ganvir2; Tuomas Kantonen2; Sneha Goel2; Antti Salminen2; Efthymios Polatidis1; 1Paul Scherrer Institute; 2University of Turku
The adverse effects of nickel ions being released into the human body have prompted the development of low nickel/nickel-free austenitic stainless steels for various applications, especially for medical applications. We are exploring the possibility to develop LPBF process for printing a novel steel, PANACEA which has not be printed before using LPBF. We present the variation of the microstructure, especially the phase volume, by changing the printing parameters and its influence to the mechanical properties.
A-51: Nano-scale Heterogeneity-driven Metastability Engineering in Ferrous Medium-entropy Alloy Induced by Additive Manufacturing: Jeong Min Park1; Peyman Asghari-Rad2; Alireza Zargaran2; Jae Wung Bae3; Jongun Moon2; Hyeonseok Kwon2; Jungho Choe1; Sangsun Yang1; Ji-Hun Yu1; Hyoung Seop Kim2; 1Korean Institute of Materials Science; 2Pohang University of Science and Technology; 3Pukyong National University
Selective laser melting (SLM) offers unprecedented advantages in fabrication of metals and alloys with complex geometry and unique microstructural features with hierarchical heterogeneity. The SLM process also induces a unique cell structure with high dislocation density and solute segregation at cell boundaries. In the present study, an innovative utilization of unique dislocation network was proposed to achieve superior mechanical properties through metastability engineering of ferrous-medium entropy alloy (FeMEA). While the high dislocation density at cell boundaries contributes to the improvement of yield strength as additional barriers of dislocation movement, the solute segregation at cell boundaries can beneficially control the phase instability of matrix in materials produced by SLM. Our results demonstrate that solute segregation at cell boundaries decreases the face-centered cubic phase stability in the matrix and activates transition of the deformation mechanism from slip to transformation-induced plasticity, which contributes the significant enhancement of strength-ductility combination of FeMEA.
A-52: Operando Synchrotron Powder XRD Reveal 316L Stainless Steel Microstructure Evolution during Additive Manufacturing: Kouider Abdesselam1; Steve Gaudez1; Hakim Gharbi1; Steven Van Petegem2; Manas Upadhyay1; 1Centre National de la Recherche Scientifique (CNRS), Ecole Polytechnique, Institut Polytechnique de Paris; 2Paul Scherrer Institute
During metal AM, solid state thermal cycling (SSTC) occurs when the as solidified material undergoes multiple heating-cooling cycles at different temperature amplitudes and rates. This could trigger mechanisms such as dislocation dynamics, phase transformation, etc., that would result in microstructure evolution and determine the material’s eventual mechanical response. To understand the role of SSTC on microstructure evolution during AM, operando synchrotron powder XRD experiments were carried out at ESRF during laser metal deposition (LMD) of 316L steel using a novel miniature LMD machine developed by us. The experiments involved following the microstructure evolution at the 20th layer during building of an 80-layer wall. In this talk, we will present the results of this experiment, specifically, the evolution of the average hkl peak positions (lattice strains), broadening (dislocation density), and intensity (texture) as a function of number of layers added and discuss the impact on the eventual mechanical response of materials.
Tailored Microstructure and Creep Behavior of Laser Powder Bed Fusion Inconel 939: Nandha Kumar Eswaramoorthy1; Sarath Chandra Reddy Karumudi2; Dheepa Srinivasan1; Vishwanath Chintapentha2; Vikram Jayaram3; Praveen Kumar3; 1Pratt & Whitney R & D Center, Indian Institute of Science, Bangalore; 2Indian Institute of Technology Hyderabad; 3Indian Institute of Science Bangalore
Laser Powder Bed Fusion (LPBF) Inconel 939 (IN939) was subjected to different short cycle heat treatments. The as-printed structure was subjected to direct aging at 800° C (DA1), at 1000°C (DA2), and 1000°C + 800°C (DA3) and was compared with solutionizing at 1190°C and aging at 1000°C+800°C (SA), to generate different microstructures with variable gamma prime γ’ precipitate sizes and volume fractions. DA1 showed partial retention of the characteristic as-printed dendritic structure along with precipitation of nano-sized tertiary gamma prime (γ’) precipitate while the other three HT’s showed the occurrence of equiaxed grains and precipitation of intra-granular η-phase (Ni3Ti) along with primary and secondary γ’ precipitates. DA1 showed the highest tensile strength and thermal stability. The effectiveness of the γ’ particle size distribution to the stability the high temperature creep behaviour, was evaluated, via uniaxial creep measurements. Crystal plasticity modeling was carried out to predict the stable creep response.
A-53: The Investigation of Copper Alloy Fabricated by Selective Laser Melting: Kangwei Chen1; Simon Ringer1; Keita Nomoto1; 1The University of Sydney
Copper and its alloys can achieve outstanding thermal and electrical conductivities, which is of great interest as a critical platform technology in the electrification revolution. Additive manufacturing (AM) offers not only the opportunity for complex build parts design due to its high degrees of freedom in the fabrication process, but also the potential to improve mechanical strengths, maintaining superior conductivity. While progress has been made in additively manufactured copper alloys, the microstructure-mechanical property-conductivity relationships remain unknown. In this study, we characterize metal powders to develop a rigorous methodology via microscopy and microanalysis techniques for quantifying copper alloy powder microstructure, connecting it to the microstructure and property of build material produced by laser powder bed fusion. Furthermore, we correlate the microstructure-mechanical property-conductivity relationships with the fabrication process toward developing advanced copper alloys with excellent structural and functional properties.