scholarly journals Investigation of Microstructure and Mechanical Performance of IN738LC Superalloy Thin Wall Produced by Pulsed Plasma Arc Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 3924
Author(s):  
Kaibo Wang ◽  
Zhe Sun ◽  
Yuxin Liu ◽  
Yaohui Lv
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Performance ◽  
Eutectic Reaction ◽  
Bimodal Distribution ◽  
High Energy ◽  
Thin Wall ◽  
Pulsed Plasma ◽  
Plasma Arc ◽  
Heat Accumulation ◽  
Energy Beam

The IN738LC Ni-based superalloy strengthened by the coherent γ′-Ni3(Al,Ti) intermetallic compound is one of the most employed blade materials in gas turbine engines and IN738LC thin wall components without macro-cracks were fabricated by pulsed plasma arc additive manufacturing (PPAAM), which is more competitive when considering convenience and cost in comparison with other high-energy beam additive manufacturing technologies. The as-fabricated sample exhibited epitaxial growth columnar dendrites along the building direction with discrepant secondary arm spacing due to heat accumulation. A lot of fine γ′ particles with an average size of 81 nm and MC carbides were observed in the interdendritic region. Elemental segregation and γ–γ′ eutectic reaction were analyzed in detail and some MC carbides were confirmed in the reaction L + MC→γ + γ′. After standard heat treatment, bimodal distribution of γ′ phases, including coarse γ′ particles (385 nm, 42 vol.%) and fine γ′ particles (42 nm, 25 vol.%), was observed. The mechanism of microstructural evolution, phase formation, as well as cracking mechanisms were discussed. Microhardness and tensile tests were carried out to investigate the mechanical performance. The results show that both the as-fabricated and heat-treated samples exhibited a higher tensile strength but a slightly lower ductility compared with cast parts.

Fabrication of circular cooling channels by cold metal transfer based wire and arc additive manufacturing

2021 ◽  
pp. 095440542199561
Author(s):  
Shaohua Han ◽  
Zhongzhong Zhang ◽  
Pengxiang Ruan ◽  
Shiwen Cheng ◽  
Dingqi Xue
Keyword(s):  
Additive Manufacturing ◽  
High Energy ◽  
Cooling Effect ◽  
High Deposition Rate ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Energy Beam ◽  
Cooling Channels ◽  
Straight Line

Additive manufacturing has been proven to be a promising technology for fabricating high-performance dies, molds, and conformal cooling channels. As one of the manufacturing methods, wire and arc additive manufacturing displays unique advantages of low cost and high deposition rate that are better than other high energy beam-based ones. This paper presents a preliminary study of fabricating integrated cooling channels by CMT-based wire and arc additive manufacturing process. The deposition strategies for fabricating circular cross-sectional cooling channels both in conformal and straight-line patterns have been investigated. It included optimizing the welding torch angle, fabricating the enclosed semicircle structure and predicting the collision between the torch and constructed part. The cooling effect test was also conducted on both the conformal cooling channel and straight-line cooling channel. The results affirmed a higher cooling efficiency and better uniform cooling effect of the conformal cooling channel than straight-line cooling channel.

scholarly journals Low-Roughness-Surface Additive Manufacturing of Metal-Wire Feeding with Small Power

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4265
Author(s):  
Bobo Li ◽  
Bowen Wang ◽  
Greg Zhu ◽  
Lijuan Zhang ◽  
Bingheng Lu
Keyword(s):  
Additive Manufacturing ◽  
High Surface ◽  
Deposition Process ◽  
High Energy ◽  
Width Ratio ◽  
Thin Wall ◽  
Small Power ◽  
High Surface Quality ◽  
Wall Structures ◽  
Wire Feed

Aiming at handling the contradiction between power constraint of on-orbit manufacturing and the high energy input requirement of metal additive manufacturing (AM), this paper presents an AM process based on small-power metal fine wire feed, which produces thin-wall structures of height-to-width ratio up to 40 with core-forming power only about 50 W. In this process, thermal resistance was introduced to optimize the gradient parameters which greatly reduces the step effect of the typical AM process, succeeded in the surface roughness (Ra) less than 5 μm, comparable with that obtained by selective laser melting (SLM). After a 10 min electrolyte-plasma process, the roughness of the fabricated specimen was further reduced to 0.4 μm, without defects such as pores and cracks observed. The ultimate tensile strength of the specimens measured about 500 MPa, the relative density was 99.37, and the Vickers hardness was homogeneous. The results show that the proposed laser-Joule wire feed-direct metal deposition process (LJWF-DMD) is a very attractive solution for metal AM of high surface quality parts, particularly suitable for rapid prototyping for on-orbit AM in space.

scholarly journals Cross-Contamination Quantification in Powders for Additive Manufacturing: A Study on Ti-6Al-4V and Maraging Steel

Materials ◽  
2019 ◽  
Vol 12 (15) ◽  
pp. 2342
Author(s):  
Eleonora Santecchia ◽  
Paolo Mengucci ◽  
Andrea Gatto ◽  
Elena Bassoli ◽  
Silvio Defanti ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Maraging Steel ◽  
Computer Aided Design ◽  
High Energy ◽  
Cross Contamination ◽  
Good Reliability ◽  
Metal Additive Manufacturing ◽  
Energy Beam ◽  
Beam Laser ◽  
Metal Additive

Metal additive manufacturing is now taking the lead over traditional manufacturing techniques in applications such as aerospace and biomedicine, which are characterized by low production volumes and high levels of customization. While fulfilling these requirements is the strength of metal additive manufacturing, respecting the tight tolerances typical of the mentioned applications is a harder task to accomplish. Powder bed fusion (PBF) is a class of additive manufacturing in which layers of metal powder are fused on top of each other by a high-energy beam (laser or electron beam) according to a computer-aided design (CAD) model. The quality of raw powders for PBF affects the mechanical properties of additively manufactured parts strongly, and therefore it is crucial to avoid the presence of any source of contamination, particularly cross-contamination. In this study, the identification and quantification of cross-contamination in powders of Ti-6Al-4V and maraging steel was performed using scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) techniques. Experimental results showed an overall good reliability of the developed method, opening the way for applications in machine learning environments.

Electron Beam Additive Manufacturing and its Applications in Aerospace Field

2014 ◽  
Vol 789 ◽  
pp. 377-383 ◽  
Author(s):  
Min Xue Li ◽  
Wen Qing Qu
Keyword(s):  
Electron Beam ◽  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Electron Beam Melting ◽  
Aircraft Engine ◽  
High Energy ◽  
Development Prospect ◽  
Rapid Manufacturing ◽  
Energy Beam ◽  
3D Print

The concept of additive manufacturing is put forward on the basis of the nowadays research hotspot-3D print. This paper focuses on the main branch technology of additive manufacturing, i.e., electron beam melting (EBM) in high energy beam rapid manufacturing area, enumerating the advantages of EBM compared with laser rapid prototyping and introducing its process principle as well as its research status. The application situation of EBM in aerospace especially it’s utility in aircraft engine and industrialization of industrial aspects was also introduced, and its development prospect in the future was forecasted.

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