Additive Manufacturing of Large-scale Metallic Components: Nickel Alloys/Hybrid Additive Manufacturing
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Additive Manufacturing Committee
Program Organizers: Sougata Roy, Iowa State University; Sneha Prabha Narra, Carnegie Mellon University; Andrzej Nycz, Oak Ridge National Laboratory; Yousub Lee, Oak Ridge National Laboratory; Chantal Sudbrack, National Energy Technology Laboratory; Albert To, University of Pittsburgh; Yashwanth Bandari, AddiTec Technologies LLC
Wednesday 2:00 PM
March 22, 2023
Room: 25A
Location: SDCC
Session Chair: Chantal Sudbrack, National Energy Technology Laboratory
2:00 PM
Effect of Cooling Rates on the α-lathe, κ Precipitates, and Reconstructed Prior-β Grains in Nickel Aluminum Bronze: Dillon Watring1; Colin Stewart1; Richard Fonda1; David Rowenhorst1; 1Naval Research Laboratory
Metal additive manufacturing (AM), specifically wire arc additive manufacturing (WAAM) has become increasingly popular for applications of large metal components due to the high deposition rate and low equipment costs compared to other metal AM techniques. Nickel aluminum bronze (NAB) has been one alloy that has been valued for its high strength, corrosion resistance, and cavitation resistance. Although WAAM techniques have shown advantages over traditionally cast components, there is a large amount of uncertainty surrounding the processing-structure-property relationships in WAAM metals. Specifically, when rapidly cooled, NAB has fine, face centered cubic (fcc) α phase that is formed from a coarse high-temperature body centered cubic (bcc) β phase, along with various κ precipitates. This work focuses on investigating the effect of cooling rates on the α-lathe size, the κ precipitates, and the reconstructed prior-β grains and the respective impact on mechanical properties in NAB.
2:20 PM
Effect of Varying Machining Conditions on Microstructure and Mechanical Properties of 316L Stainless Steel Fabricated by Hybrid Manufacturing: Rangasayee Kannan1; Thomas Feldhausen1; Peeyush Nandwana1; 1Oak Ridge National Laboratory
By interleaving additive and subtractive manufacturing processes, it has been shown that hybrid manufacturing can significantly increase the part fabrication rates compared to additive manufacturing and post-fabrication machining. Hybrid manufacturing technology comes with scientific challenges, especially understanding the effect of interleaving deposition and machining on the microstructure and performance of the fabricated parts. In this talk, we will present results on the effect of varying the machining conditions, specifically, the effect of varying the spindle speed and the presence/absence of coolant during machining on the microstructure and mechanical performance of 316L parts. Apart from the as-fabricated condition (AM + machined), the effect of machining conditions used during fabrication on the microstructure development during post-fabrication heat treatments will also be discussed.
2:40 PM
Hybrid Metal Manufacturing of Large Freeform Geometries: Bradley Jared1; Tony Schmitz1; Joshua Penney1; Aaron Cornelius1; Ross Zameroski1; Eduardo Miramontes1; Tiffany Quigley1; Devon Goodspeed1; William Hamel1; 1University of Tennessee, Knoxville
The timely fabrication of large, complex metallic structures is a persistent challenge for America’s industrial base as schedules for large parts, i.e one to two feet cube and larger, are routinely defined in months and years; introducing unacceptable risk and cost for most products. On-going work is addressing these challenges using a large-scale hybrid metal manufacturing system which combines multi-material metal inert gas (MIG) deposition, fringe projection scanning metrology, part handling and five-axis machining. The integration, capabilities and challenges of the hybrid process flow will be demonstrated through the processing of mild steel structures. Geometric control of final part shape is a research focus as work is addressing multiple elements associated with part distortion due to internal stresses, complex geometry path planning, real-time process monitoring and control, and finish machining.
3:00 PM Invited
From Neutron Diffraction to Tool Repair: How Fundamental Scientific Research Translates to Industrial Impact for Hybrid Manufacturing Systems: Thomas Feldhausen1; Kyle Saleeby1; Peeyush Nandwana1; Rangasayee Kannan1; Alex Plotkowski1; Brian Post1; 1Oak Ridge National Laboratory
The convergence of multiple manufacturing techniques and processing domains has enabled new uses of existing manufacturing equipment in novel workflows. For example, integration of additive, subtractive, and inspection techniques by means of hybrid manufacturing has enabled manufacturers to reduce labor and material costs by mitigating disjointed processing. While these systems are more capable, the science of interleaving multiple operations is complex. Fundamental understanding of factors like residual stress, microstructure evolution, and geometric distortion in these complex processes remains the primary barrier to success. This presentation details how research into the fundamental understanding of hybrid processes is being translated to real-world applications. Covering specific developments like a wire-arc hybrid machine installed in ORNL's Spallation Neutron Source and the development of the world's largest metal-wire laser DED hybrid system, the audience will gain an appreciation of the challenges and future opportunities for hybrid AM systems.
3:30 PM Break
3:50 PM
Large Area Deposition of Haynes 230: Sergio Ausejo1; Laura Acebo1; Nerea Burgos1; David Linder2; Savya Sachi2; Ida Berglund2; Mustafa Megahed3; 1CEIT; 2QuesTek Europe AB; 3ESI Group
Powder-based direct energy deposition (p-DED) is pursued to repair and enhance surface properties of large components. Its wide application is limited by the trade-off between process efficiency (e.g., deposition rates) and the deposits' quality (e.g., porosity, cracks, detrimental phases). This work showcases the integration of multi-scale multi-physics computational and experimental methods (ICME) in optimizing the laser cladding process of Haynes 230, by addressing the key process-structure relationships. Numerical simulations are supported by materials thermo-physical properties predicted by the CALPHAD-based approach and are used to assess the melt pool stability and crack susceptibility. Comparison of process simulations with experimental data show good agreement in that high deposition rates are difficult to achieve. Larger laser spot sizes tend to lead to melt pool instabilities, while smaller spot sizes lead to less instability but to higher thermal loads and cracking. The compromise achieved is discussed and possible process optimization is briefly presented.
4:10 PM
Design, Modeling and Optimization of a Light Weight Impact Attenuator for Commercial Vehicles Using Wire Arc Additive/Subtractive Manufacturing (WAASM) Processing: Mohamed Fawzy Mohamed1; Hanadi Salem1; Islam Hamdy1; Ahmed Elsokaty1; 1The American University in Cairo
Wire arc additive/subtractive manufacturing (WAASM) is a novel and promising technique, which employs metallic wires and electrical arc to deposit metallic parts with medium-to-high geometrical complexity. Although, this method requires additional post-processing time to deal with lower resolution and relatively poor surface finish, it is advantageous due to the effective control of the residual stresses and structural anisotropy, and the lower cost and availability of metallic wires.In the current research, design and manufacturing of a commercial light weight honey-comb shock absorption attenuator was carried out. Design optimization with variable built walls geometries was done with an objective of energy absorption maximization, weight and cost reduction, which were subject to structural integrity constraints such as strength, stiffness and buckling resistance. Impact simulation tests were run on ABAQUS and results are discussed to validate the chosen parameters. Quasi-static compression and structural integrity were used for characterization of the WAAM built structures.
4:30 PM
The Effect of Cryogenic Cooling on the Microstructure and Mechanical Properties of Wire Arc Additively Manufactured Steels: Constantinos Goulas1; Maximus Akuh2; Vignesh Venkata Subramanian3; Remco Rook3; José Galán Argumedo4; Theodoros Michelis4; Marco Ameye2; Wei Ya3; Ian Gibson1; Marcel Hermans4; 1University of Twente; 2AirProducts; 3RAMLAB BV; 4Delft University of Technology
A dominating factor largely limiting the deposition rates in Wire + Arc Additive Manufacturing (WAAM) is the waiting time related to temperature management. During WAAM deposition of large constructs, the welding of each bead is commonly followed by significant cooling time. Supplementing the WAAM process with cryogenic cooling address these limitations and enables a steep increase in production rates. A cryogenic cooling solution and a temperature and process monitoring system were integrated into a multi-robot WAAM setup, reducing cooling times up to 70%. Single and multi-bead walls were deposited at high deposition rates (5Kg/hr) using this cryogenic cooling system. The materials studied in this work include deposits of structural steel, austenitic stainless steel and martensitic stainless steel. The microstructural and texture evolution of cryogenically cooled WAAM samples is discussed and compared with non-cooled samples, oftentimes leading to a positive effect on the mechanical properties of the WAAM products.
4:50 PM Invited
Wire-Arc Additive Manufacturing of Haynes® 282 Superalloy: Wei Xiong1; Luis Ladinos Pizano1; Soumya Sridar1; Chantal K. Sudbrack2; 1University of Pittsburgh; 2National Energy Technology Laboratory
Wire-Arc Additive manufacturing (WAAM) is a directed energy deposition technique suitable for large-scale metallic component printing and has potential for power plant components. Using Gefertec® ARC 605, the feasibility of WAAM for large-scale printing of Haynes 282 superalloy is demonstrated with careful process optimization, resulting in high-quality builds in the wall and cone-shape geometries. The cyclic heating and cooling process introduced the complexity with residual stress and columnar grain structure and thus required further post-heat treatment optimization. Combining CALPHAD-based ICME tools and high-throughput experiments, an ad hoc post-heat treatment was designed to reduce anisotropy in microstructure-property correlations and optimize microstructure, yielding comparable strength to the alloys made by traditional processes. This work demonstrates that although the WAAM is ready for large component fabrication and repairing, appropriate design of heat treatment according to the process-structure-property relationships is critical. Moreover, the location-specific design should be considered to ensure the mechanical performance of the large-scale prints.