Additive Manufacturing: Materials Design and Alloy Development V – Design Fundamentals: Design Fundamentals
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee, TMS: Integrated Computational Materials Engineering Committee
Program Organizers: Behrang Poorganji, Morf3d; Hunter Martin, HRL Laboratories LLC; James Saal, Citrine Informatics; Jiadong Gong, Questek Innovations LLC; Orlando Rios, University of Tennessee; Atieh Moridi, Cornell University
Monday 8:30 AM
March 20, 2023
Room: 24C
Location: SDCC
Session Chair: Behrang Poorganji, Morf3D; James Saal, Citrine Informatics
8:30 AM Introductory Comments Behrang Poorganji. Morf3D
8:35 AM Invited
In-Situ Alloying As An Approach for Alloy Development: Does It Work?: Moataz Attallah1; 1University of Birmingham
This talk highlights the utility of in-situ alloying during laser powder bed fusion, as an approach for alloy development. Case studies featuring materials with different chemistries will be explored, including Beta Ti-alloys, Al-X alloys, and refractory metals. Comparisons between the microstructure-property development in in-situ alloyed and pre-alloyed chemistries, will be shown. Overall, the success of in-situ alloying relies heavily on the differences in melting temperatures between the various alloying elements.
9:05 AM Invited
Algorithmic Design of Functionally Graded Alloys: Raymundo Arroyave1; Marshall Allen1; Tanner Kirk2; Richard Malak1; 1Texas A&M University; 2Questek
Functional grading has recently seen renewed interest with the advancement of additive manufacturing. Unfortunately, the integrity of functional gradients in alloys tends to be compromised by the presence of brittle phases. Recently, CALPHAD-based tools have been used to generate isothermal phase diagrams that are in turn utilized to plan gradient paths that avoid these phases. However, existing frameworks rely extensively on the (limited) ability of humans to visualize and navigate high-dimensional spaces. In this talk, we present some recent advancements toward the development of algorithmic approaches to design functionally graded alloys. The framework leverages computational thermodynamic predictions, machine learning, path planning and roadmapping to identify trajectories in composition space that result in controllable property/performance profiles while avoiding the formation of detrimental phases. Concepts on multi-material design leveraging this framework are also presented.
9:35 AM Invited
Grain Refinement in Fusion Based Additive Manufacturing: Mark Easton1; Duyao Zhang1; Dong Qiu1; 1RMIT University
One of the less desirable aspects of fusion-based additive manufacturing is the formation of coarse columnar grain structures crossing build layers. This presentation explains the reason for the formation of columnar grain structures. Successful approaches to the grain refinement of titanium alloys using alloying elements that produce constitutional supercooling are discussed along with the difficulty with nucleant additions. Much of the grain-refining technology already used in aluminium casting is shown to also be applicable to additive manufacturing, although the novelty of the effective use of nanoparticles as nucleants is highlighted. It is also shown that for other alloy systems for which there is a lack of grain-refining technology using chemical means, mechanical means, such as ultrasonic treatment, can be effective across a wide range of alloys. Finally, the importance of understanding nucleation in solidification conditions characterized by high cooling rates and thermal gradients is considered.
10:05 AM Break
10:20 AM Invited
ICME-guided Design of Ni-based Superalloy Coatings for High-temperature Industrial Applications: Ida Berglund1; Savya Sachi1; David Linder1; Fuyao Yan1; 1Questek Europe AB
Powder-based direct energy deposition (p-DED) process has been pursued in repairing and enhancing the surface properties of large components, e.g. beams and rings operating at high temperatures and corrosive environments in industrial furnaces, with creep and wear identified as the primary failure modes. This work aims to showcase the integration of multi-scale and multi-physics computational methods, i.e., Integrated Computational Materials Engineering (ICME), in addressing the key process-structure and structure-property relationships in the laser-cladded Haynes 230 alloy. The developed ICME framework allows for accelerated design and refinement of alloy composition (including impurity levels) and the associated processing parameters for improved combination of deposited materials properties and process efficiency, while reducing the need for costly and time-consuming experimental trials. Interaction between the steel substrate and the cladding is also discussed.
10:50 AM Invited
Additive Manufacturing of Inconel 718
by Meltpool and Grain Boundary Engineering: Frank Abdi1; Vasyl Harik1; Mallikharjun Marrey1; Amir Eftekharian1; Rashid Miraj1; 2; 1Alphastar Technology Solutions LLC; 2Imperial College London
Additive Manufacturing (AM) offers a new paradigm in design of alloys with complex microstructure. Integrating materials technology, materials design and manufacturing innovation is a new frontier of AM development. The objective is to develop 1) meltpool engineering with process and void maps to characterize thermal history and porosity of AlSi10Mg, and 2) grain boundary engineering of alloy composition and grain size for different AM process parameters. AM parts 3D-printed by Laser Power Bed Fusion (LPBF) need to be qualified for (i) defects (micro, macro), (ii) net-shape warpage, (iii) high residual stresses, (iv) surface roughness, (v) voids, (vi) anisotropic microstructures due to variable cooling rates, and (vii) scatter in mechanical properties. AM defects (e.g., unfused powder, balling, humping, and keyholing) are affected by variations in power and speed as well as hatch spacing. Predictions for i) voids and density maps for AlSi10Mg, and ii) stress-strain curves are compared with experimental data.
11:20 AM
Grain Boundary Engineering of New Additive Manufactured Polycrystalline Alloys: Abhishek Kumar1; Mallikharjun Marrey2; Veera Sundararaghavan3; Frank Abdi2; 1Wentworth Institute of Technology; 2AlphaStar Corporation; 3University of Michigan
A novel idea to create new alloys for Additive manufacturing (AM) by mixing a small addition of nanoparticles with bulk material was put forward. Integrated Computational Material Engineering (ICME) may be used to guide the AM process, predict thermal behaviour, optimize process parameters, secure net-shape, and qualify parts. Modelling is needed to predict the effect of defects and the effect of inclusions on mechanical properties, build quality and in-service performance. ICME can reduce trial-and-error fabrication and establish an AM digital twin, thereby accelerating part qualification and AM adoption. AM creates complex thermal processes which impact material microstructure and result in changes to mechanical properties in terms of strength and plasticity. In this study, Grain-Boundary Engineering (GBE) and multi-scale modelling are performed to expedite qualification of new and existing AM polycrystalline alloys.