Powder Materials Processing and Fundamental Understanding: Additive Manufacturing II
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Powder Materials Committee
Program Organizers: Kathy Lu, Virginia Polytechnic Institute and State University; Eugene Olevsky, San Diego State University; Hang Yu, Virginia Polytechnic Institute and State University; Ruigang Wang, The University of Alabama; Isabella Van Rooyen, Pacific Northwest National Laboratory

Tuesday 8:00 AM
March 1, 2022
Room: 263C
Location: Anaheim Convention Center

Session Chair: Ruigang Wang, The University of Alabama; Isabella Van Rooyen, Pacific Northwest National Laboratory

8:00 AM  
Additive Manufacturing of Ionic Liquids Harvested Metal for Martian Habitation: Blake Stewart1; Haley Doude1; Jennifer Edmunson2; Eric Fox2; Hongjoo Rhee1; 1Mississippi State University; 2National Aeronautics and Space Administration
    As the race to establish a sustainable human presence on Mars continues, the need for energy efficient, low-waste manufacturing techniques remains a major hurdle. Launching building materials from Earth is not feasible financially; therefore, in-situ resource utilization (ISRU) methods are required to ensure the success and longevity of Martian habitats. Ionic liquids (IL) are currently studied at NASA’s Marshall Space Flight Center (MSFC) to harvest metallic elements from regolith and meteorites. IL technology provides a low-temperature method to extract critical manufacturing materials, such as iron (Fe), that can be used for structures, plumbing, and tools. In this study, IL-sourced Fe (IL-Fe) was used as feedstock for selective laser melting (SLM) to obtain a baseline of material characteristics for extraterrestrial additive manufacturing. Produced samples were investigated by microstructure, hardness, and chemical composition analyses. In-situ sourced IL-Fe showed potential as a feedstock for production of metallic materials via laser-based additive manufacturing technique.

8:20 AM  
Challenges Associated with Micro-additive Manufactured 316L and 17-4PH Stainless Steel Components Produced by Binder Jet and Selective Laser Melting: Michael Pires1; Chia-chun Chao1; Gregory Pawlikowski2; Abe Shocket2; Bradley Schultz2; Martin Bayes2; Masashi Watanabe1; Wojciech Misiolek1; 1Lehigh University; 2TE Connectivity Corporation
    Over the previous two decades, microfabrication technologies have been developed due to the high demand in micro-sized components. Current additive manufacturing (AM) technologies have already made adequate progress in producing small scale components, but the fabrication of micro parts can introduce further challenges. A comparative study between 316L and 17-4PH stainless steel alloys for both additive and micro-additive manufactured (micro-AM) components was conducted to examine the resulting microstructure and mechanical performance. Components were produced via binder jet, selective laser melting, and print & sinter. Microstructural characterization of AM and micro-AM components was investigated using light optical (LOM) and scanning electron (SEM) microscopy. Consideration was taken for mechanical properties at scale and the resulting surface quality of micro-AM components with the use of micro-indentation and tensile measurements.

8:40 AM  
Direct Powder Combination, Consolidation, and Forming of Metals and Composites via Solid-state Additive Manufacturing: Robert Griffiths1; Hunter Rauch1; Hang Yu1; 1Virginia Polytechnic Institute
    Additive friction stir deposition (AFSD) is a solid-state additive manufacturing technique capable of processing a wide range of metal systems. In one configuration of the technology, powder material is fed through a hollow tool via a differentially rotating auger screw, much like many pellet-fed polymer extruders. Unlike these, at the end of the tool the accumulated powder is further consolidated via severe shear deformation which also bonds the material to a substrate or previous layer. By feeding different types of powder into the process, full density composites and alloys can be formed in-situ, with the additive nature of the technique producing desired shapes and structures as well. Here we focus on an Aluminum-Molybdenum system produced via this technique. The thermomechanical conditions during AFSD are ideal for mechanically induced mixing, producing a unique hybrid composite structure with extremely high loading fraction of reinforcement, full density, and good mechanical response.

9:00 AM  
Effect of Powder Reuse on Mechanical Behavior of Additively Manufactured Ti-6Al-4V: Shuai Shao1; Arash Soltani-Tehrani; Nima Shamsaei1; 1Auburn University
    Powder bed fusion technology is a common additive manufacturing (AM) method, which utilizes powder as the feedstock. After fabrication, the used powder is often recycled for subsequent fabrications due to the extensive costs associated with powder atomization and handling. Therefore, there is a need for a systematic investigation to understand the effects of powder reuse on the AM part performance. This study aims to methodically inspect how the powder reuse can influence its characteristics, and consequently, the defect content, tensile, and fatigue performance of parts fabricated via laser beam powder bed fusion (LB-PBF) and plasma-atomized Ti-6Al-4V powder. In addition, parts will be fabricated in different locations on the build plate to reveal any locational dependencies of micro-/defect-structural and mechanical properties and correlate these dependencies with the powder reuse.