scholarly journals Development of Al-TiC Wire Feedstock for Additive Manufacturing by Metal Screw Extrusion

Metals ◽  
2020 ◽  
Vol 10 (11) ◽  
pp. 1485
Author(s):  
Geir Langelandsvik ◽  
Mathieu Grandcolas ◽  
Kristian G. Skorpen ◽  
Trond Furu ◽  
Odd M. Akselsen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Grain Morphology ◽  
Electric Arc ◽  
Grain Refining ◽  
Alloy Development ◽  
Screw Extrusion ◽  
Accumulated Strain ◽  
Alloy Addition ◽  
Tic Nanoparticles ◽  
Arc Deposition

The development of customised aluminium alloys for welding and additive manufacturing (AM) is proposed to solve several quality issues and to enhance the mechanical integrity of components. The introduction of ceramic grain refining agents shows great potential as alloy addition as to limit cracking susceptibility and increase the strength. Thus, a versatile solid-state manufacturing route for nanoparticle reinforced aluminium wires has been developed based on the metal screw extrusion principle. In fact, the Al-Si alloy AA4043 mixed with 1 wt.% TiC nanoparticles has been manufactured as a wire. The accumulated strain on the material during metal screw extrusion has been estimated, classifying the process as a severe plastic deformation (SPD) method. A chemical reaction between silicon and TiC particles after metal screw extrusion was found, possibly limiting the grain refining effect. Electric arc bead-on-plate deposition was performed with metal screw extruded and commercial material. The addition of TiC induced a grain morphology transition from columnar to equiaxed after electric arc deposition, and increased the hardness. A high amount of porosity was found in the AA4043-TiC material, probably arising from hydrogen contamination on TiC surfaces prior to metal screw extrusion. The results are encouraging as a new direction for aluminium alloy development for additive manufacturing.

scholarly journals Wire arc additive manufacturing of AA5183 with TiC nanoparticles

2021 ◽  
Author(s):  
Geir Langelandsvik ◽  
Magnus Eriksson ◽  
Odd M. Akselsen ◽  
Hans J. Roven
Keyword(s):  
Additive Manufacturing ◽  
Grain Refinement ◽  
Aluminium Alloys ◽  
The Novel ◽  
Grain Refiner ◽  
Screw Extrusion ◽  
Coarse Microstructure ◽  
Tic Nanoparticles ◽  
Wire Arc Additive Manufacturing ◽  
Extrusion Method

AbstractAluminium alloys processed by wire arc additive manufacturing (WAAM) exhibit a relatively coarse microstructure with a columnar morphology. A powerful measure to refine the microstructure and to enhance mechanical properties is to promote grain refinement during solidification. Addition of ceramic nanoparticles has shown great potential as grain refiner and strengthening phase in aluminium alloys. Thus, an Al-Mg alloy mixed with TiC nanoparticles was manufactured by the novel metal screw extrusion method to a wire and subsequently deposited by WAAM. Measures to restrict oxidation of magnesium during metal screw extrusion were examined. Purging of CO2 gas into the extrusion chamber resulted in a remarkable reduction in formation of MgO and Mg(OH)2. TiC decomposed to Al3Ti during WAAM deposition, leading to a significant grain refinement of 93% compared to a commercial benchmark. The presence of remaining TiC nanoparticles accounted for an increased hardness of the WAAM material through thermal expansion mismatch strengthening and Orowan strengthening. Exposure of TiC to moisture in air during metal screw extrusion increased the internal hydrogen content significantly, and a highly porous structure was seen after WAAM deposition.

scholarly journals Wire and Arc Additive Manufacturing with TiC-Nanoparticle Reinforced AA5183 Alloy

2020 ◽  
Vol 326 ◽  
pp. 07002
Author(s):  
Geir Langelandsvik ◽  
Olav Ragnvaldsen ◽  
Jan E. Flåm ◽  
Odd M. Akselsen ◽  
Hans J. Roven
Keyword(s):  
Additive Manufacturing ◽  
Aluminium Alloy ◽  
High Strength ◽  
Ceramic Composites ◽  
Hydrogen Trapping ◽  
Fine Grained ◽  
Extrusion Processing ◽  
Screw Extrusion ◽  
Order Of Magnitude ◽  
Tic Nanoparticles

Wire and arc additive manufacturing of aluminium-ceramic composites shows great potential to produce high strength materials. By incorporation of nanoparticles in the feedstock wire, fine-grained material with low susceptibility for solidification cracking and enhanced strength can be obtained. In fact, this study utilised the novel screw extrusion method to prepare an aluminium alloy containing TiC nanoparticles. The commercial aluminium alloy AA5183 was selected for WAAM to assess and benchmark the effects of screw extrusion and TiC. The materials have been assessed in terms of microstructure, porosity content and mechanical properties. The presence of TiC reduced the average grain diameter by 70%, while Vickers hardness increased with 13%. However, number of pores per unit volume increased by one order of magnitude. The porosity is believed to stem from hydrogen introduced in the AA5183-material through screw extrusion processing, in addition to hydrogen trapping and pore nucleation on TiC nanoparticles.

scholarly journals Compression Behaviour of Wire + Arc Additive Manufactured Structures

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 877
Author(s):  
Masoud Abbaszadeh ◽  
Volker Ventzke ◽  
Leonor Neto ◽  
Stefan Riekehr ◽  
Filomeno Martina ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Grain Morphology ◽  
Electron Back Scatter Diffraction ◽  
Compression Tests ◽  
Homogeneous Microstructure ◽  
Compression Loading ◽  
Anisotropic Behaviour ◽  
Mechanical And Microstructural Properties ◽  
Wire Arc Additive Manufacturing

Increasing demand for producing large-scale metal components via additive manufacturing requires relatively high building rate processes, such as wire + arc additive manufacturing (WAAM). For the industrial implementation of this technology, a throughout understanding of material behaviour is needed. In the present work, structures of Ti-6Al-4V, AA2319 and S355JR steel fabricated by means of WAAM were investigated and compared with respect to their mechanical and microstructural properties, in particular under compression loading. The microstructure of WAAM specimens is assessed by scanning electron microscopy, electron back-scatter diffraction, and optical microscopy. In Ti-6Al-4V, the results show that the presence of the basal and prismatic crystal planes in normal direction lead to an anisotropic behaviour under compression. Although AA2319 shows initially an isotropic plastic behaviour, the directional porosity distribution leads to an anisotropic behaviour at final stages of the compression tests before failure. In S355JR steel, isotropic mechanical behaviour is observed due to the presence of a relatively homogeneous microstructure. Microhardness is related to grain morphology variations, where higher hardness near the inter-layer grain boundaries for Ti-6Al-4V and AA2319 as well as within the refined regions in S355JR steel is observed. In summary, this study analyzes and compares the behaviour of three different materials fabricated by WAAM under compression loading, an important loading condition in mechanical post-processing techniques of WAAM structures, such as rolling. In this regard, the data can also be utilized for future modelling activities in this direction.

scholarly journals Grain refining of Ti-6Al-4V alloy fabricated by laser and wire additive manufacturing assisted with ultrasonic vibration

2021 ◽  
Vol 73 ◽  
pp. 105472
Author(s):  
Ding Yuan ◽  
Shuaiqi Shao ◽  
Chunhuan Guo ◽  
Fengchun Jiang ◽  
Jiandong Wang
Keyword(s):  
Additive Manufacturing ◽  
Ultrasonic Vibration ◽  
Grain Refining

scholarly journals Recent Studies and Developments in Titanium Biomaterials

2020 ◽  
Vol 321 ◽  
pp. 02004
Author(s):  
M. Ikedaa ◽  
M. Ueda ◽  
M. Ninomi
Keyword(s):  
Health Care ◽  
Additive Manufacturing ◽  
Titanium Alloys ◽  
Young’S Modulus ◽  
Young's Modulus ◽  
Layer By Layer ◽  
Metal Powders ◽  
Alloy Development ◽  
Dental Surgery ◽  
Artificial Bones

Titanium and its alloys have a high specific strength, excellent corrosion resistance, and good biocompatibility. Therefore, these alloys are adopted as raw materials for artificial bones and joints. Furthermore, these alloys are used as materials for dental surgery. In the development of alloy design, beta-type titanium alloys that possess a lower Young’s modulus than other types of titanium alloys, e.g., Ti-6Al-4V alpha-beta-type alloys, are being actively investigated worldwide. Based on these studies, titanium-niobium-tantalum and zirconium system alloys were developed. For example, Ti-29Nb-13Ta-4.6Zr alloy has a low Young’s modulus, excellent biocompatibility, and improved mechanical properties. Many researchers are actively investigating surface modifications and surface treatments. Additive manufacturing, namely 3D printing, wherein metal powders are piled up layer by layer to produce goods without a mold, has attracted attention in many fields, including manufacture of implants, especially porous structural implants with a low Young’s modulus. It is very important that titanium and its alloys be applied to health-care goods, e.g., wheelchairs and prostheses. Therefore, we herein consider four topics: alloy development, coating and surface modification, additive manufacturing, and health care applications.

scholarly journals Effect of pulsating disintegrating airflow on electric arc depositing

2021 ◽  
Vol 9 (3B) ◽  
Author(s):  
Mohammad E. Matarneh ◽  
◽  
Vyacheslav Royanov ◽  
Irina Zakharova ◽  
◽  
...  
Keyword(s):  
Bond Strength ◽  
Bonding Strength ◽  
Metal Removal ◽  
Electric Arc ◽  
Pulsation Frequency ◽  
Process Performance ◽  
Frequency Range ◽  
Optimum Frequency ◽  
Electrical Arc ◽  
Arc Deposition

To limit the losses in sprayed metal in the process of electric arc deposition, the disintegrating airflow is pulsated. In this work, the effect of changing the pulsation frequency was studied on the process performance, mainly, the efficiency of metal removal and rate of deposition. Additionally, the bonding strength of the resulting sprayed metal was evaluated at different pulsation frequencies. The application of air pulsations increases the productivity and efficiency of sprayed material by increasing the efficiency of material used up to 30% and enhancing the rate of deposition up to 32%, at a frequency range 70–80 Hz. Moreover, at the optimum frequency of air pulsations, the bond strength increased up to 69%, measured by Steffensen’s dowel method. The results found in this work will allow for more rational usage of the electrical arc energy and material.

scholarly journals Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5370
Author(s):  
Geir Langelandsvik ◽  
Odd M. Akselsen ◽  
Trond Furu ◽  
Hans J. Roven
Keyword(s):  
Aluminum Alloy ◽  
Additive Manufacturing ◽  
Alloy Composition ◽  
Layer By Layer ◽  
Alloy Development ◽  
And Performance ◽  
Crack Susceptibility ◽  
Wire Arc Additive Manufacturing ◽  
Further Development ◽  
Complex Parts

Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

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