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Meeting 2024 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing: Process-induced Microstructures and Defects
Presentation Title F-49: Nanotechnology-enabled Wire Arc Direct Energy Deposition of Aluminum Alloy 2024
Author(s) Yitian Chi, Xiaochun Li
On-Site Speaker (Planned) Yitian Chi
Abstract Scope With a high specific strength and good fatigue resistance, aluminum alloy AA2024 has drawn enormous attention from both industry and academia. Despite the advantages offered by AA2024, it cannot be manufactured via fusion-based printing because of hot cracking and other solidification problems. Nano-treating is an emerging nanotech metallurgy method that uses a small fraction of nanoparticles to enhance alloy manufacturability and properties. This work shows the unprecedented success of nanotechnology-enabled wire-arc direct energy deposition of nano-treated AA2024 components. The resulting parts were crack-free with fine and equiaxed grains at an average size of 23.2 ± 0.4 μm. Microhardness profiles show homogeneous mechanical performance along the build direction, regardless of cyclic thermal exposure. Finally, excellent tensile strength and elongation up to 428 MPa and 7.4% were achieved after heat treatment. The combined results show a great promise of nanotechnology in Additive Manufacturing of high-strength aluminum alloys.
Proceedings Inclusion? Planned:
Keywords Nanotechnology, Additive Manufacturing, Aluminum

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

A Microstructure Study of Multi-Mode Laser Profiles
Additive Manufacturing in Reactive Atmospheres
Additive Process Parameter Optimisation, Heat Treatment and High Cycle Fatigue of Ti6242
Aiming the Susceptibility to Weld Solidification Cracking in Nickel-based Alloys Produced by Laser 3D Printing Processes
Analysis of Porosity Defects and Their Impact on Tensile Behavior in LPBF Stainless Steel 316L Utilizing X-ray Computed Tomography
Batched Additive Manufacturing Meets Parallel Bayesian Optimization – Highway for Materials Design
Characterization of Microstructure and Mechanical Property Variation in Haynes 282 as a Function of Laser Powder Bed Fusion Process Parameters
Characterization of Ti-6Al-4V Microstructure Development in Laser Powder Bed Fusion with Preheat as a Variable Printing Parameter
Comparing and Optimising Continuous Wave and Pulsed Width Modulation Mode Laser Powder Bed Fusion Parameters for Ti-6Al-4V
Correlation of Keyhole Geometry with Spatters and Droplets during Laser Powder Bed Fusion Additive Manufacturing of Aluminium
Correlations of Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing
Critical Comparison of Advanced Non-destructive Evaluation Technologies Identifying Cracking in Laser Powder Bed Fusion Components
Custom-Post-Process Heat Treatments to Eliminate Columnar Microstructure in W-DED Ti-6Al-4V
Development of a Digital Twin for Laser Powder Bed Fusion of A205 Al-Alloy
Development of Process Conditions of L-PBF for a Novel High-Entropy Alloy
Dispersoid Coarsening and Slag Formation during Melt-based Additive Manufacturing of ODS Superalloys
Effect of Deposition Sequence on the Interfacial Characteristics of Additively Manufactured Stainless Steel 316L/Inconel 718 Multi-material Structures
Effect of Heat Treatment Condition on the Mechanical Properties of Laser-Powder Bed Fusion-Processed 18Ni300 Maraging Steel
Effect of Laser Irradiation Mode on L-PBF Ti6Al4V Thin Sections
Effect of Powder Based, Metal AM Processing Parameters on Resulting Grcop-42 Specimens
Effect of Scan Strategy on Texture and Single-crystal Structure Formations in Laser Powder Bed Fusion of Pure Ni with a Flat-top Laser Beam
Elimination of Solidification and Strain-Age Cracking Through Inoculation-Induced Grain Refinement in IN738
Enhancing the Productivity in Laser Powder Bed Fusion through Functionally Graded Structures
Evaluation of Porosity in Aluminum Deposits
Evaluation of Processing Conditions and Post-Heat Treatment of Quasicrystal Reinforced Candidate Al Alloy for Additive Manufacturing
F-34: Characterization of Microstructure and Defects in a CrMnFeCoNi High-Entropy Alloy Processed by Multi-Beam Laser Directed Energy Deposition
F-35: Characterization of Surface Integrity and Mechanical Properties in XM-19 Alloy Manufactured by Powder Bed Fusion with Various Process Parameters
F-37: Determination of Process Parameters from Bead-on-Plate Experiments for AA6061 in Laser Powder Bed Fusion
F-38: Effect of Induction Heating Temperature on Inconel 718 Deposited by Induction-heating-assisted Laser-directed Energy Deposition
F-39: Effects of Low-temperature Heat Treatment on Mechanical and Thermophysical Properties of Cu-10Sn Alloys Fabricated with Laser Powder Bed Fusion
F-40: Evolution of Precipitate Structure and Composition as a Function of Heat Input for Additive Friction Stir Deposition of AA7050
F-41: Influence of Process Parameters on Mechanical Behavior of 316L Stainless Steel Samples Processed by Wire-Laser Directed Energy Deposition
F-42: Investigating the Relationship between Interfacial Microstructure and Joint Strength in Ultrasonically-Welded Ni/Al/Ni Multilayer Composites
F-43: Laser Powder Bed Fusion of Pure Iron
F-44: Microscopy Image Post Processing Accelerated with an Open-sourced Image Alignment and Blending Program.
F-45: Microstructural Evolution and Anisotropy in Stainless Steel 316L from Wire Arc Additive Manufacturing
F-46: Microstructure and Mechanical Characterization of AISI 4340 Steel Additively Manufactured by Laser Powder Bed Fusion
F-48: Microstructure and Mechanical Properties of Triple Weld Bead Wire Arc Additively Manufactured ER70s-6
F-49: Nanotechnology-enabled Wire Arc Direct Energy Deposition of Aluminum Alloy 2024
F-51: Prediction of Build Geometry to Prevent Lack of Fusion and Bead Stacking in Arc Wire Directed Deposition (AW-DED)
F-52: Process-Induced Texture Formation in 316L Stainless Steel Samples Processed by Laser Wire Directed Energy Deposition
F-53: Processing, Microstructure and Mechanical Properties of Multi-layer Friction Surfacing in 7075 Aluminium Alloy
F-54: Room and Cryogenic Mechanical Properties and Microstructure of Additively Manufactured CrNiMn Steels
F-55: Secondary Phase Characterisation of Wire Arc Additive Manufactured Superalloys
F-56: Surface Heterostructuring of Laser-clad 316L Stainless Steel Through Texture-driven Deformation Twinning
F-57: The Effect of Deposition Offset on Material Flow for Solid-state Volumetric Restoration of Al-Zn-Mg-Cu Alloy via Friction Stir Additive Manufacturing
F-58: Thermally-Stable Invar-Cu Intrinsic Composites Formed by Laser Powder Bed Fusion
F-59: Understanding Role of Sintering Environment on Densification Behavior and Mechanical Properties of Binder Jet Shell Printed Parts
F-60: Using Part-scale In-situ Defect Formation Monitoring to Predict Fatigue Performance in LPBF
F-61: Variable Mechanical Properties in Additively Manufactured Components Using Profilometry-based Indentation Plastometry (PIP)
F-71: Microstructural and Mechanical Properties of Parts Produced through the Bound-Metal FFF Additive Manufacturing Process
F-72: Mechanical and Microstructural Characterization of DED Additively Manufactured QT 17-4+ Steel
F-73: Additive Manufacturing of a Martensitic Chromium Steel: Process Parameters, Microstructure and Mechanical Properties
Flaw Type and Build Orientation Dependent Creep Strength of 316L Stainless Steel Fabricated via Laser Powder Bed Fusion
Giant Supersaturation of Interstitial Light Atoms in Laser Powder Bed Fusion Processed Stainless Steel 316L via Solute Trapping
Gleeble Dilatometry to Resolve Microstructure Evolution in W-DED Ti-6Al-4V
Gleeble Simulations of Stainless Steels to Understand Correlations between Build Height, Thermal History, Microstructure, and Mechanical Properties in AM
High-Temperature Mechanical and Oxidation Performance of Additive Friction Stir Deposited IN625
In-situ Monitoring and Defect Detection of Direct Energy Deposition Process
In-Situ Monitoring of Melt Pool Temperature, Size, and Cooling Rate of Directed Energy Deposition Inconel 625 and Correlations to Microstructure and Mechanical Properties
Influence of LPBF Build Parameters on Process-induced Defect Characteristics and Mechanical Properties in Ti-6Al-4V
Influence of Mo Micro-particles on Crack Formation, Microstructure, and Mechanical Behaviour of Laser Powder Bed Fusion Fabricated CuZrAl Bulk Metallic Glass Composites
Influence of Solidification Parameters on the Microstructure of Inconel 625 Processed by Direct Energy Deposition
Investigating Al(FeMn)Si Nanoprecipitate Formation in Hybrid Wire Arc Additively Manufactured (HWAAM) Aluminum
Investigating Build Orientation-induced Mechanical Anisotropy in Additive Manufacturing 316L Stainless Steel
Investigating the Influence of Controlling Aluminium Alloy Powder Characteristics on the Directed Energy Deposition Process
Isolating The Effects of Microstructure on the Mechanical Performance of PBF-L Ti-6Al-4V
Laser Influences on Heterogeneity in Powder Bed Fusion Aluminum with Reactive Additions Studied by X-ray Microtomography
Leveraging Metastability in High Entropy Alloys for Grain Refinement in Additive Manufacturing
Manipulation of Microstructure of Additively Manufactured 316L Stainless Steels Using Diverse Scan Strategies
Metastable Phase Formation in a High-Strength Aluminum Alloy Fabricated Using Additive Manufacturing
Microstructural and Mechanical Analysis of As-Built and Heat-Treated Maraging Steel 300 Fabricated via Laser Powder Bed Fusion
Microstructural and Mechanical Characteristics of Binder Jet Processed AISI M2 High-Speed Tool Steel
Microstructural Changes and Defect Evolution on Powder Bed Fusion Processed 316L Austenitic Stainless Steel
Microstructure Analysis on Laser Remelting of Medium- and High-Entropy Alloys: Towards Enhanced Printability
Microstructure and Mechanical Effects of Inter-layer Machine Hammer Peening on Wire Arc Additively Manufactured Nickel Superalloys
Microstructure and Properties of Additively Manufactured Aluminum Alloys Containing Quasicrystalline Dispersoids
Multiscale Gradient Strengthening of Additively Manufactured Low Alloy Martensitic Steel
Nanoparticles-Enabled Laser Powder Bed Fusion of High Strength 6061 Aluminum Alloy
Observations of Keyhole Porosity and Comparisons to Analytical Models for Ti-6Al-4V Powder Bed Fusion
Optimizing Mechanical Properties of Additive Manufactured Alloy through Taguchi Analysis and Intermetallic Phase Quantification via Image Processing
Optimizing the DED 3D Printing Process for Improved Microstructure and Mechanical Performance
Porosity Predictions in Additively Manufactured Al-10Si-0.4Mg and Ti-6Al-4V Alloys Using a Geometric Model
Powder Recyclability and the Effect of Recycled Powder on the Microstructure and Mechanical Behavior of 316L Stainless Steel Manufactured by Directed Energy Deposition
Predicting the Unique Microstructures of Inoculated High Strength Aluminum Alloys Processed with Wire Arc Additive Manufacturing
Processing of Novel and Commercial Titanium Alloys by Laser Track Melting and the Role of Phase Stability on As-built Microstructure
Scanning Strategies: A Tool to Control Cracking in Crack Susceptible Ni-based Superalloy CM247LC
Selective Laser Melting of High-temperature Al-TM Based Alloys
SLM-induced Microstructures and Properties of Ni Hastelloy X under Extreme Conditions
Solid State Deposition of Inconel Super Alloy: Structure and Property Relationship
Temperature and Strain Rate Behavior of Electron Beam Additively Manufactured Inconel 718
The Effects of Novel Heat Treatments on The Microstructure of PBF-L Ti-6Al-4V
The Response of 3D Printed 17-4 PH to Heat Treatment
Understanding the Geometry-dependent Microstructure in Complex Ti-6Al-4V Parts Fabricated by Laser Powder Bed Fusion
Understanding the Microstructure and Chemical Evolution of Al-Mg alloys Prepared by Hybrid Casting and Additive Manufacturing Processes
Unveiling Metal Additive Manufacturing Microstructure through Data-Driven Unsupervised Clustering of Crystallographic Texture
Using high frequency beam oscillation to control melt pool dynamics in laser melting revealed by in-situ x-ray imaging
Volumetric Tailoring of Porosity and Grain Structure in Binder Jetting
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