Additive Manufacturing and Innovative Powder/Wire Processing of Multifunctional Materials: Structural 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
Wednesday 8:30 AM
March 22, 2023
Room: 23C
Location: SDCC
Session Chair: Iver Anderson, Iowa State University Ames Laboratory
8:30 AM Invited
Functional and Structural Materials Enabled by Advanced Manufacturing: Ryan Ott1; Emrah Simsek1; Rakesh Chaudhary1; Seungjin Nam1; Jun Cui1; Matthew Kramer1; 1Ames National Laboratory
Advanced functional and structural materials, which are essential to clean energy technologies, often rely on non-equilibrium processing (e.g., rapid solidification) to develop their desired properties. Advanced manufacturing techniques such as additive manufacturing (AM) and extrusion processing provide opportunities for exploiting non-equilibrium processing to synthesize functional and structural materials with complex geometries and architectures while also potentially reducing critical materials usage. Here we discuss using AM to rapidly optimize compositions of different materials with decreased critical usage as well as synthesis of components with tailored structure and properties. Specific examples include directed energy deposition of permanent magnet alloys and development of Al alloys for AM synthesis and extrusion processing.
9:00 AM
Development of Metallic Matrix Composites and Powders for Metal Additive Manufacturing (MAM) Technologies: James Rosero-Romo1; Paula G. Saiz1; Daniel Salazar1; 1BCMaterials, Basque Center for Materials, Applications and Nanostructures
Environmental preservation has become a key issue in the search for new materials. In this context, reducing fuel consumption is a topic of great interest. To this end, industries related to the manufacture of parts for aircraft and automobiles have focused on developing new additive manufacturing technologies such as Wire Arc Additive Manufacturing (WAAM) or Atmospheric Pressure Plasma Deposition (APPD) as well as the use of new materials with improved properties as feedstock for these technologies; materials that at the end of the additive manufacturing process provide low densities but with mechanical properties equal to or better than those of traditional materials. In this work, we will present the most relevant results obtained on the development and characterization of aluminium matrix composites (AMCs) with ceramic nanoparticle reinforcement as well as on the development of Mo and Diamond powders with surface nanocoatings to improve their thermal coupling into metallic matrixes.
9:20 AM
Microstructure Evolution and Mechanical Behavior of Ni-NiAl Functionally Integrated Materials (FIMs) Processed via Directed Energy Deposition (DED): Xin Wang1; Baolong Zheng1; Benjamin MacDonald1; Calvin Belcher1; Penghui Cao1; Lorenzo Valdevit1; Enrique Lavernia1; Julie Schoenung1; 1University of California, Irvine
Ni-Al intermetallic systems are attractive materials for high-temperature structural applications due to their high strength, but exhibit limited ductility. Recently, directed energy deposition (DED) techniques have demonstrated the ability to control local chemistry in a build through the co-deposition of dissimilar powder feedstocks, providing a approach to spatially tune chemistry and mechanical behavior. In this talk, two powder feedstocks, Ni and pre-alloyed NiAl, are co-deposited in the DED process to fabricate heterogeneous samples with site-specific structural modulations named functionally integrated materials (FIMs). Compositional transitions from Ni to NiAl are obtained to assess the effective mixing of the two feedstock materials during DED. The non-equilibrium microstructural evolution, including the phase formation and compositional variations, are investigated using SEM/EDS, XRD and TEM techniques. The mechanical properties are evaluated as a function of position along with the transition. The experimental results are also compared to the predictions of phase stability calculated through CALPHAD.
9:40 AM
Effect of Wire Directed Laser Energy Deposition Parameters and Heat Treatment on the Microstructure and Mechanical Properties of NAB C95800: Ryan Doyle1; Somayeh Pasebani1; Jakub Preis1; 1Oregon State University
A nickel aluminum bronze (NAB) wire with chemical composition of Cu-8.64Al-4.2Ni-3.2Fe V(wt%) was processed via directed laser energy deposition. This study investigates the effects of process parameters and post process heat treatment on the NAB microstructure and resulting mechanical properties. Single track depositions were measured and characterized for macro defects to determine optimal parameter sets. Laser powers of 800-1200 W and print head traverse speeds of 300-900 mm/s were varied in nitrogen atmosphere to produce characterization samples. Scanning electron microscopy was utilized to observe the microstructure and elemental dispersion. Energy dispersive X-ray spectroscopy revealed a single ferritic phase of the as printed sample. Annealing heat treatment of 675 C for 6 hours was performed on the as printed DED sample. Microhardness and tensile tests were conducted to obtain mechanical properties. The microstructures and mechanical properties of the as printed and heat-treated samples were analyzed and compared.
10:00 AM Break
10:15 AM
Fatigue Behavior of Additively Manufactured Haynes 230 at Room and Elevated Temperatures: Muztahid Muhammad1; Rukesh Gusain1; Reza Ghiaasiaan1; Paul Gradl2; Shuai Shao1; Nima Shamsaei1; 1Auburn University; 2NASA Marshall Space Flight Center
This study investigated and compared fatigue behavior of Haynes 230 manufactured using two additive manufacturing (AM) technologies, namely, laser powder bed fusion and laser powder directed energy deposition. Original cylindrical rods went through similar multi-step heat treatments (HT), including stress relief, hot isostatic pressing, and solution treatment, and then were machined to the final geometry of standard test specimens. Fully-reversed, strain-controlled fatigue tests were conducted at room and different elevated temperatures. Microstructure and fracture surfaces were analyzed utilizing a scanning electron microscope. The micro-segregation and dendritic feature in the non-heat treated microstructure of both alloys were almost completely dissolved after full HT, and M6C/M23C6 carbide phases were formed at grain interiors and at grain boundaries. Finally, failure mechanisms of both alloys were discussed and compared. The fatigue fracture surfaces of both alloys consisted of microstructural facets as crack initiation sites instead of AM process-induced volumetric defects.
10:35 AM
On Enhancing the Mechanical Properties of DED Fabricated Ti–6Al–4V by Boron Addition and In-situ Reheating: Kavindu Wijesinghe1; Ajit Achuthan1; 1Clarkson University
Additive manufacturing (AM) technologies for metals and alloys, in many cases, yield inferior mechanical properties under as-built conditions. The inferior properties are generally attributed to the large columnar grains with the strong texture of AM fabricated parts. This study investigates two methods to enhance the mechanical properties of directed energy deposited (DED) Ti-6Al-4V alloy. The first method involves modifying the material chemistry by boron addition up to 1.5 wt%, while the second method involves in-situ reheating. Specimens with various amounts of boron additives and subjected to in-situ reheating are printed. Then, their mechanical properties and microstructure are characterized using various experimental techniques. Preliminary results show that increasing boron addition decreased anisotropy gradually. Likewise, the in-situ reheating process improved tensile properties. Efforts to derive a comprehensive understanding of the mechanism responsible for the influence of boron addition and in-situ reheating on microstructure refinement and mechanical properties are currently ongoing.
10:55 AM
Ceramic Reinforced Graded Metal Matrix Composites Using Directed Energy Deposition: Alberto Canales Cantu1; Shashank Sharma1; Yuqi Jin1; Sameehan Joshi1; Narendra Dahotre1; 1University of North Texas
B4C ceramic reinforced metal matrix composites were produced in layers of varying amount of reinforcement using setup equipped with multi-hopper system. Process optimization was conducted through multiphysics computational process modeling. The effect of the increasing amount of reinforcement was evaluated along the gradation direction using nanoindentation hardness testing and non-destructive effective bulk modulus elastography. The mixing and interfacial characteristics were evaluated using high resolution transmission electron microscopy. A composite with highest fraction of reinforcement on the surface was produced which exhibited a hard surface and a smooth gradation of hardness in the interior regions.
11:15 AM
Hollow-Strut Metal Lattices by Laser Powder Bed Fusion: Jordan Noronha1; Ma Qian1; Martin Leary1; Milan Brandt1; Elizabeth Kyriakou1; 1Royal Melbourne Institute of Technology
A combination of civil and mechanical engineering, hollow-strut lattices are an emerging subset of periodic cellular materials achieving high mechanical efficiency. The conventional method of hollow-strut lattice manufacture is inefficient, however, with long lead times, an exhaustive combination of fabrication processes, and geometrical constraints that restrict access from the broader research community. Laser powder bed fusion (LPBF) offers an alternative, improving manufacturability of these structures with greater geometrical control, efficient lead times, and enabling the fabrication of higher density lattices. The mechanical performance of LPBF-manufactured Ti6Al4V and AlSi10Mg hollow-strut lattices observe yield strengths of up to 53MPa for a given relative density of 15.6%, surpassing the majority of conventional solid-strut lattices. However, these structures were observed to be weakened due to premature node buckling. By exploiting the internal channels to reinforce the nodes, enhanced strengths are achievable. This research enables lattices with high-strength functionality to expand design flexibility and applications.
11:35 AM
Friction Stir Additive Manufacturing Bulk Metal Matrix Composites: Andrew Yob1; Shiqin Yan1; Michael Kellam1; David Renshaw1; Ling Chen1; Michel Givord1; Daniel Liang1; Robert Wilson1; 1CSIRO
Bulk metal matrix composites (MMCs) can be produced by stir and filtration casting or solid-state deposition and sintering. The microstructures of the MMCs produced, especially the by casting methods, have various shortcomings, including particle segregation, coarse matrix grains or dendrites, and low high fraction of the ceramic particles. Recently, an emerging approach based on friction stir additive manufacturing (FSAM) for fabricating bulk aluminium (Al) alloy MMCs has demonstrated potentials to overcome the microstructural shortcomings. This study focuses on microstructural characterization and mechanical testing of these bulk Al alloy MMCs that are formed by FSAM. Microstructures of these Al alloy MMCs are examined in terms of the size, fraction and distribution of the added particles and the refinement of the Al phase in the matrix. The characteristics of the microstructures is correlated with significant improvement of hardness and mechanical properties of the bulk Al alloy MMCs.
11:55 AM Invited
Additive Manufacturing of Soft and NdFeB Bonded Permanent Magnets: Prospects and Challenges: Parans Paranthaman1; 1Oak Ridge National Laboratory
Additive manufacturing (AM) or 3D printing is well known for producing parts without any tooling required, offering a promising alternative to the conventional methods to fabricate near-net-shaped functional magnets. We will report our successful fabrication of Fe-3Si; Fe-6Si and FeCo soft magnets with properties comparable to that of traditionally made magnets using selective laser melting. We will also compare two different binders with material extrusion followed by compression molding, to determine their applicability in the fabrication of Nd-Fe-B bonded magnets. Prospects and challenges of these state-of-the-art technologies for large-scale industrial applications will be discussed. This work was supported by the Critical Materials Institute, an Energy Innovation Hub funded by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Materials and Manufacturing Technologies Office and Office of Energy Efficiency and Renewable Energy, Wind Energy Technology Office.