Additive Manufacturing and Innovative Powder/Wire Processing of Multifunctional Materials: Steels II
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

Thursday 2:00 PM
March 23, 2023
Room: 23C
Location: SDCC

Session Chair: Emily Rinko, Honeywell Fm&T; Emma White, DECHEMA Forschungsinstitut


2:00 PM  
Directed Energy Deposition of AF9628: Process Optimization and Overhang Compensation: Clara Mock1; Josh Taggart-Scarff2; Brandon McWilliams1; Franklyn Kellogg3; 1DEVCOM Army Research Laboratory; 2SURVICE Engineering; 3US Army DEVCOM Army Research Laboratory
    Process parameters for high strength, high hardness AF9628 steel were successfully developed for Directed Energy Deposition (DED) to enable the creation of large-scale parts with complex features such as internal overhang features. The deposition efficiency for unsupported layers decreases rapidly for overhangs of a critical angle (often quoted as 10 degrees from the vertical) resulting in a failure to build the overhang section of the part. AF9628 DED process development was conducted by varying laser power, speed and layer height to build weld tracks, small walls and cubes. Parameters were down selected based on evenness of weld tracks, minimum porosity and hardness. The overhang compensation was investigated for overhang angles from 20-45° as a function of contour speed from 381-1016 mm/min (15-40 in/min). Part geometry was investigated by measuring the overhang angle with a coordinate measuring machine and roughness via confocal microscopy.

2:20 PM  
Process-microstructure-mechanical Property Correlations of a 3D Printed Austenitic Steel – From Powder Bed Fusion to Directed Energy Deposition: Shubham Chandra1; Xipeng Tan2; Upadrasta Ramamurty1; 1Nanyang Technological University; 2National University of Singapore
    Stainless steel type 316L is a low-carbon chromium-nickel-molybdenum austenitic steel. Due to its remarkable corrosion resistance and excellent mechanical properties, it has been applied to many fields such as food, architecture, aircraft, and automotive industries – ranging from cryogenic to intermittent temperature applications. Ergo, 316L (SS) stands as a perfect candidate for advancing the application of metal AM techniques to the mainstream manufacturing sectors. This talk will present the unique microstructural evolution and mechanical response of 316L (SS) printed using two mainstream metal AM techniques – electron beam powder bed fusion (EB-PBF) and laser-directed energy deposition (L-DED). The effect of processing conditions, process parameters, and part geometries on the melt pool solidification parameters, grain growth and deformation mechanisms are explored through experimental investigations and computational modelling. Moreover, innovative printing strategies are discussed that provide improved control of grain growth during solidification.

2:40 PM  Cancelled
Thermal-Stress Modeling during DED Hybrid Technology Using 316L Stainless Steel: Mukesh Kalel1; Pedro Cortes1; Kyosung Choo1; Jose Angel Diosdado De la Pena1; Eric Haake1; 1Youngstown State University
    The study has performed a finite element analysis to simulate the thermal and mechanical behavior during a DED (Laser+ Hot Wire Based) additive manufacturing process. The computational work was carried out using ANSYS 2021 R2 software. The experiment was performed with 316L stainless steel using MAZAK VC-500A/5X HWD (Hot wire Deposition) 3D printer. The temperature contour/profile during the printing was recorded using a FLIR IR (A600 Series) thermal camera which was later compared with the temperature data obtained from the ANSYS simulation. The emissivity of the IR thermal camera was determined by temperature data obtained from the thermocouples attached to the base plate of the built. For the mechanical analysis, the built part was scanned using CREAFORM 3D scan camera which provided the deformation of the part due to the heat generation during printing. The deformation result obtained from the 3D Scan was then compared with simulation for validation.

3:00 PM  
Microstructure and Mechanical Properties of 17-4PH Stainless Steels Manufactured by Material Extrusion Additive Manufacturing: Yong-Hoon Cho1; So-Yeon Park1; Ju Yong Kim2; Kee-Ahn Lee1; 1Inha University; 2Reprotech
    Metal Material Extrusion Additive Manufacturing (M-MEAM) is a building process by extruding a filament composed of metal powders and polymer binder layer-by-layer. M-MEAM has been getting interest because of its superior economic feasibility and accessibility than other metal AMs. In this study, 17-4PH stainless parts were manufactured by using M-MEAM with post sintering process. And subsequent heat treatments (HT) were also conducted. Its microstructure and mechanical properties were investigated according to HT conditions. Microstructure observation demonstrated that the fraction and distribution of precipitations, such as nm size Cu-rich phase, were varied by HT conditions. Tensile test results showed that the HT could improve the tensile strength to 1.34 GPa, the yield strength to 1.1 GPa and the elongation to 7.6 %, which were close to ASTM wrought material’s properties. The deformation and fracture mechanisms of 17-4PH alloy manufactured by M-MEAM was also discussed in relation with the microstructures.

3:20 PM  
Additive Manufacturing of Multi-material Metal Structures Using Powders Produced by Machining: Puli Saikiran1; Harish Dhami1; Priti Panda1; Koushik Viswanathan1; 1Indian Institute of Science
    Graded multi-material structures (GMMS) are engineered to exhibit spatially controlled heterogeneous properties. These structures are usually built using metal additive manufacturing (AM), employing gas or plasma atomized stock powders, and have emerged as promising solutions in many applications. Yet, the use of these structures has been severely limited by the high cost of powder material. This work demonstrates the use of powders produced via machining that promises to be a potential alternative route for producing GMMS. Metal powders (SS304 and IN625) of various sizes and morphologies are produced via conventional multipoint milling with suitable tool path design and process parameter control. Powders are then controllably delivered using a customized delivery system that specifically handles non-spherical particles. GMMS ranging from multiscale architected materials to blended in-situ alloys are then fabricated using a conventional laser-based AM system. Their performance was quantified using a range of ex-situ microstructural analysis techniques and mechanical testing.

3:40 PM Break

3:55 PM  
Alloy Development through In-situ Mixing of Stainless Steel 316L and Inconel 718 Using Directed Energy Deposition: Noah Sargent1; Samad Firdosy2; Kinga Unocic3; Jonathan Poplawsky3; Richard Otis2; Wei Xiong1; 1University of Pittsburgh; 2Jet Propulsion Laboratory, California Institute of Technology; 3Center for Nanophase Materials Sciences, Oak Ridge National Laboratory
    Additive manufacturing is a powerful tool for rapid prototyping and alloy design. However, the cyclic heating and cooling of melting processes often result in large columnar grains that dominate the as-printed microstructure, causing strong texture with anisotropic properties that limit the application of additive manufacturing. In this work, we apply powder-based directed energy deposition to discover new alloys with refined grains using mixtures of Inconel 718 superalloy (IN718) and stainless steel 316L (SS316L). The oxidation behavior of the SS316L and IN718 mixtures at 800°C is investigated to study the impact of composition on oxide scale formation. We have further performed mechanical tests of SS316L and IN718 multi-material joints after post-heat treatment guided by the CALPHAD tools.

4:15 PM  
In-situ Synthesis of Invar Alloys by Dual-wire Deposition Using WAAM: Arjun Sood1; Jim Schimmel1; Constantinos Goulas2; Vera Popovich1; Marcel Hermans1; 1Delft University of Technology; 2University of Twente
    Invar alloys are known and widely employed for their dimensional stability. These alloys have uniquely low thermal expansion up to the Curie temperature. This magnetic phase transition temperature in the Invar alloy system varies with the Ni content. Consequently, Invar alloys are flexible for use in a broad temperature range depending on the Ni content. In this respect, wire and arc additive manufacturing presents the opportunity for in-situ alloying through multi-wire deposition. Therefore, this study utilises a dual-wire deposition approach to fabricate a graded Invar wall and a block of Invar 42. We present and discuss the prime aspects of the in-situ deposited Invar alloy concerning the deposition, composition and thermal expansion coefficient.

4:35 PM  
Laser Beam Directed Energy Deposition of High-Si Content Fe-Si Soft Magnetic Alloys: Andrew Kustas1; Don Susan1; Todd Monson1; Sarah Birchall1; Shaun Whetten1; Mark Wilson1; Kyle Johnson1; Jonathan Pegues1; Erin Barrick1; 1Sandia National Laboratories
     Fe-Si (i.e., electrical steel) alloys possess favorable electromagnetic properties, such as high magnetic permeability/saturation induction, low coercivity/core loss and high electrical resistivity, ideal for electric motors and transformers. The addition of Si into Fe enhances the electromagnetic properties to create more efficient power devices, with peak alloy performance near 6.5 wt.% Si. Unfortunately, despite opportunities for enhancing energy efficiency via the use of high-Si content electrical steels, widespread commercial adoption of this alloy composition has yet to be achieved due to poor material ductility, making conventional manufacturing impractical. Laser beam directed energy deposition (LB-DED) additive manufacturing (AM) is presented as a viable route for producing bulk geometries of a high Si-content Fe-6wt.%Si alloy. Microstructure and magnetic properties of the LB-DED Fe-6wt.%Si alloy are characterized and benchmarked against wrought low-Si and other AM-processed high-Si content alloys.SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525

4:55 PM  
Additive Manufacturing of Titanium/Diamond Metal Matrix Composites: Cherry Chen1; Robert Wilson1; Geoff de Looze1; Kun Yang1; 1CSIRO
    Titanium and its alloys with high strength-to-weight ratio, are widely used in space infrastructures, aircrafts, automotive and biomedical applications. The relatively low thermal conductivity (7.07 W/m·K) and wear resistance of titanium hinders its application in space propulsion system and power applications, which require both high thermal conductivity and high strength. Diamond is an excellent heat dissipation material, with thermal conductivity up to 2000 W/m·K. In this study, LENS™ directed energy deposition was used for the first time to 3D print titanium/diamond metal matrix composites with different diamond loading fractions by individually controlled powder feeding systems. The processing parameters were adjusted to achieve a high diamond loading up to 50 wt.%. The density, porosity, microstructure, thermal and mechanical properties of the composites were studied. A significant improvement of thermal conductivity and a bone matched modulus of the composites were achieved, showing a high potential in space and biomedical applications.