Additive manufacturing of Ti6Al4V parts using ultrasonic assisted direct energy deposition

2020 ◽  
Vol 59 ◽  
pp. 545-556
Author(s):  
A.I. Gorunov
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Direct Energy Deposition ◽  
Ultrasonic Assisted ◽  
Direct Energy

Microstructure evolution along build direction for thin-wall components fabricated with wire-direct energy deposition

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Janmejay Dattatraya Kulkarni ◽  
Suresh Babu Goka ◽  
Pradeep Kumar Parchuri ◽  
Hajime Yamamoto ◽  
Kazuhiro Ito ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Microstructural Evolution ◽  
Microstructure Evolution ◽  
Energy Deposition ◽  
Direct Energy Deposition ◽  
Content Type ◽  
Layer Deposition ◽  
Different Types ◽  
Direct Energy ◽  
Solidification Phenomenon

Purpose The use of a gas metal arc welding-based weld-deposition, referred to as wire-direct energy deposition or wire-arc additive manufacturing, is one of the notable additive manufacturing methods for producing metallic components at high deposition rates. In this method, the near-net shape is manufactured through layer-by-layer weld-deposition on a substrate. However, as a result of this sequential weld-deposition, different layers are subjected to different types of thermal cycles and partial re-melting. The resulting microstructural evolution of the material may not be uniform. Hence, the purpose of this study is to assess microstructure variation along with the lamination direction (or build direction). Design/methodology/approach The study was carried out for two different boundary conditions, namely, isolated condition and cooled condition. The microstructural evolution across the layers is hypothesized based on experimental assessment; this included microhardness, scanning electron microscopy imaging and electron backscatter diffraction analysis. These conditions subsequently collaborated with the help of thermal modeling of the process. Findings During a new layer deposition, the previous layer also is subject to re-melt. While the newly added layer undergoes rapid cooling through a combination of convection, conduction and radiation losses, the penultimate layer, sees a slower cooling curve due to its smaller exposure area. This behavior of rapid-solidification and subsequent re-melting and re-solidification is a progressing phenomenon across the layers and the bulk of the layers have uniform grains due to this remelt-re-solidification phenomenon. Research limitations/implications This paper studies the microstructure variation along with the build direction for thin-walled components fabricated through weld-deposition. This study would be helpful in addressing the issue of anisotropy resulting from the distinctive thermal history of each layer in the overall theme of metal additive manufacturing. Originality/value The unique aspect of this paper is the postulation of a generic hypothesis, based on experimental findings and supported by thermal modeling of the process, for remelt-re-solidification phenomenon followed by temperature raising/lowering repetitively in every layer deposition across the layers. This is implemented for different types of base plate conditions, revealing the role of boundary conditions on the microstructure evolution.

Anwendungszentrum für additive Fertigung/Center for Applied Additive Manufacturing – Influence of process parameters during high-speed laser direct energy deposition

2021 ◽  
Vol 111 (06) ◽  
pp. 368-371
Author(s):  
Sebastian Greco ◽  
Marc Schmidt ◽  
Benjamin Kirsch ◽  
Jan C. Aurich
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Energy Deposition ◽  
Influence Of Process Parameters ◽  
Direct Energy Deposition ◽  
Additive Fertigung ◽  
Powder Bed ◽  
High Productivity ◽  
Direct Energy ◽  
Near Net Shape

Additive Fertigungsverfahren zeichnen sich durch die Möglichkeit der endkonturnahen Fertigung komplexer Geometrien aus. Die geringe Produktivität etablierter Verfahren wie etwa dem Pulverbettverfahren hemmen aktuell den wirtschaftlichen Einsatz additiver Fertigung. Das Hochgeschwindigkeits-Laserauftragschweißen (HLA) soll durch deutlich erhöhte Auftragsraten und somit bisher unerreicht hoher Produktivität bei der additiven Fertigung dazu beitragen, deren Wirtschaftlichkeit zu steigern.   Additive manufacturing enables the near-net-shape production of complex geometries. The low productivity of established processes such as powder bed processes is currently limiting the economic use of additive manufacturing. High-speed laser direct energy deposition (HS LDED) is expected to improve the economic efficiency of additive manufacturing by significantly increasing deposition rates and thus previously unattained high productivity.

scholarly journals Hybrid additive manufacturing of steels and alloys

2020 ◽  
Vol 7 ◽  
pp. 6
Author(s):  
Vladimir V. Popov ◽  
Alexander Fleisher
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Modern Trend ◽  
Production Chain ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing

Hybrid additive manufacturing is a relatively modern trend in the integration of different additive manufacturing techniques in the traditional manufacturing production chain. Here the AM-technique is used for producing a part on another substrate part, that is manufactured by traditional manufacturing like casting or milling. Such beneficial combination of additive and traditional manufacturing helps to overcome well-known issues, like limited maximum build size, low production rate, insufficient accuracy, and surface roughness. The current paper is devoted to the classification of different approaches in the hybrid additive manufacturing of steel components. Additional discussion is related to the benefits of Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) approaches for hybrid additive manufacturing of steel components.

scholarly journals Machine Learning for Competitive Grain Growth Behavior in Additive Manufacturing Ti6Al4V

2020 ◽  
Vol 321 ◽  
pp. 03004
Author(s):  
Jinghao Li ◽  
Manuel Sage ◽  
Xianglin Zhou ◽  
Mathieu Brochu ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Additive Manufacturing ◽  
Grain Boundary ◽  
Grain Growth ◽  
Manufacturing Industry ◽  
Energy Deposition ◽  
Growth Behavior ◽  
Direct Energy Deposition ◽  
Direct Energy ◽  
Grain Growth Behavior ◽  
Metal Additive

Metal additive manufacturing (MAM) technology is now changing the pattern of the high-end manufacturing industry, among which MAM fabricated Ti6Al4V has been far the most extensively investigated material and attracts a lot of research interests. This work established a deep neural network (DNN) to investigate the grain boundary in competitive grain growth for a bi-crystal system, the column β grains of Ti6Al4V as an example. Because of the limited number of experimental samples, the DNN is trained based on the data coming from the Geometrical Limited criterion. A series of direct energy deposition experiment using Ti6Al4V is carried out under the Taguchi experimental design. The grain boundary angles between the column grains are measured in the experiment and used to evaluate the accuracy of DNN.

scholarly journals Direct Energy Deposition of TiAl for Hybrid Manufacturing and Repair of Turbine Blades

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4392
Author(s):  
Silja-Katharina Rittinghaus ◽  
Janett Schmelzer ◽  
Marcus Willi Rackel ◽  
Susanne Hemes ◽  
Andreas Vogelpoth ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Phase Distribution ◽  
Turbine Blades ◽  
High Energy ◽  
Hybrid Manufacturing ◽  
Chemical Compositions ◽  
Compression Tests ◽  
Direct Energy Deposition ◽  
Direct Energy

While repair is mainly used to restore the original part geometry and properties, hybrid manufacturing aims to exploit the benefits of each respective manufacturing process regarding either processing itself or resulting part characteristics. Especially with the current implementation of additive manufacturing in the production of TiAl, turbine blades for both hybrid manufacturing and repair new opportunities are enabled. One main issue is the compatibility of the two or more material types involved, which either differ regarding composition or microstructure or both. In this study, a TNMTM-alloy (Ti-Nb-Mo) was manufactured by different processes (casting, forging, laser additive manufacturing) and identically heat-treated at 1290 °C. Chemical compositions, especially aluminum and oxygen contents, were measured, and the resulting microstructures were analyzed with Scanning Electron Microscopy (SEM) and High-energy X-ray diffraction (HEXRD). The properties were determined by hardness measurements and high-temperature compression tests. The comparison led to an overall assessment of the theoretical compatibility. Experiments to combine several processes were performed to evaluate the practical feasibility. Despite obvious differences in the final phase distribution caused by deviations in the chemical composition, the measured properties of the samples did not differ significantly. The feasibility of combining direct energy deposition (DED) with either casting or laser powder bed fusion (LPBF) was demonstrated by the successful build of the dense, crack-free hybrid material.

scholarly journals Additive Layer Manufacturing using Metal Deposition

Metals ◽  
2020 ◽  
Vol 10 (4) ◽  
pp. 459
Author(s):  
Patrice Peyre
Keyword(s):  
Additive Manufacturing ◽  
Laser Cladding ◽  
Energy Deposition ◽  
Metal Deposition ◽  
Direct Energy Deposition ◽  
Additive Layer Manufacturing ◽  
Layer Manufacturing ◽  
Direct Energy ◽  
Wire Feeding ◽  
Manufacturing Techniques

Among the additive layer manufacturing techniques for metals, those involving metal deposition, including laser cladding/Direct Energy Deposition (DED, with powder feeding) or Wire and Arc Additive Manufacturing (WAAM, with wire feeding), exhibit several attractive features [...]

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