Additive Manufacturing: Alloy Design to Develop New Feedstock Materials III: Modeling and Experiments
Sponsored by: TMS Alloy Phases Committee
Program Organizers: Aurelien Perron, Lawrence Livermore National Laboratory; Joseph McKeown, Lawrence Livermore National Laboratory; Manyalibo Matthews, Lawrence Livermore National Laboratory; Peter Hosemann, University of California, Berkeley; Christian Leinenbach, Empa, Swiss Federal Laboratories for Materials Science and Technology
Monday 10:00 AM
October 18, 2021
Room: A111
Location: Greater Columbus Convention Center
Session Chair: Aurelien Perron, Lawrence Livermore National Laboratory
10:00 AM
Insights into Additive Manufacturability and Microstructure Evolution from Simple Analytical Models: Charles Smith1; Madeleine Johnson1; Olivia DeNonno1; Luc Hagen1; Daniel Gifford1; Juan Gonzalez1; Anthony Petrella1; Zhenzhen Yu1; Amy Clarke1; Jonah Klemm-Toole1; 1Colorado School of Mines
Fusion based metal additive manufacturing, in its many forms, is a highly complex and dynamic process involving heat and mass transfer, solidification, and solid-state phase transformations. Despite these complex phenomena, valuable insights can be obtained from using simple analytical models to predict solidification conditions that relate to the likelihood of hot cracking or the tendency to form an equiaxed grain structure. In this presentation, we show how thermodynamic and heat transfer simulations can be combined with analytical solidification models to screen high temperature alloys for additive manufacturability. For selected cases, we compare predictions from these simple models to experimental results and discuss the role of alloy composition in affecting additive manufacturability. We demonstrate that modeling is accessible even to the non-modeler, and that there is significant value in using the results of simple analytical models to guide alloy exploration and experimentation.
10:20 AM Invited
A High-throughput Method to Define New Feedstock Process Parameters in Additive Manufacturing: Zahabul Islam1; Ankur Agrawal1; Behzad Rankouhi1; Frank Pfefferkorn1; Dan Thoma1; 1University of Wisconsin
This study demonstrates how a newly introduced analytical and experimental method can be used to define the processing settings for a new alloy feedstock where the additive manufacturing process parameters were previously unknown. To assess the effectiveness of this technique, a nickel-based superalloy, Haynes 282, was chosen for the analysis. An experimental matrix of processing parameters was predicted with a dimensionless number and 100 samples were printed. High-throughput (HT) characterization using both density and hardness measurements of individual samples validated the predicted process conditions. The process was completed in 16 hours. The new technique was confirmed with analytical processing maps being adopted by the metal additive manufacturing community. With the predicted best process setting, detailed microstructural characterization and mechanical properties were investigated and compared to standard properties of Haynes 282. The results demonstrate an effective strategy to validate the high-throughput design technique for new feedstock materials.