Review on laser directed energy deposited aluminum alloys

Lightweight aluminum(Al)alloys have been widely used in frontier fields like aerospace and automotive industries,which attracts great interest in additive manufacturing(AM)to process high-value Al parts.As a mainstream AM technique,laser-directed energy deposition(LDED)shows good scalability to meet the requirements for large-format component manufacturing and repair.However,LDED Al alloys are highly challenging due to their inherent poor printability(e.g.low laser absorption,high oxidation sensitivity and cracking tendency).To further promote the development of LDED high-performance Al alloys,this review offers a deep understanding of the challenges and strategies to improve printability in LDED Al alloys.The porosity,cracking,distortion,inclusions,element evaporation and resultant inferior mechanical properties(worse than laser powder bed fusion)are the key challenges in LDED Al alloys.Processing parameter optimizations,in-situ alloy design,reinforcing particle addition and field assistance are the efficient approaches to improving the printability and performance of LDED Al alloys.The underlying correlations between processes,alloy innovation,characteristic microstructures,and achievable performances in LDED Al alloys are discussed.The benchmark mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized.This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys.Future opportunities and perspectives in LDED high-performance Al alloys are also outlined.

Printability disparities in heterogeneous material combinations via laser directed energy deposition:a comparative study

Additive manufacturing provides achievability for the fabrication of bimetallic and multi-material structures;however,the material compatibility and bondability directly affect the parts’formability and final quality.It is essential to understand the underlying printability of different material combinations based on an adapted process.Here,the printability disparities of two common and attractive material combinations(nickel-and iron-based alloys)are evaluated at the macro and micro levels via laser directed energy deposition(DED).The deposition processes were captured using in situ high-speed imaging,and the dissimilarities in melt pool features and track morphology were quantitatively investigated within specific process windows.Moreover,the microstructure diversity of the tracks and blocks processed with varied material pairs was comparatively elaborated and,complemented with the informative multi-physics modeling,the presented non-uniformity in mechanical properties(microhardness)among the heterogeneous material pairs was rationalized.The differences in melt flow induced by the unlike thermophysical properties of the material pairs and the resulting element intermixing and localized re-alloying during solidification dominate the presented dissimilarity in printability among the material combinations.This work provides an in-depth understanding of the phenomenological differences in the deposition of dissimilar materials and aims to guide more reliable DED forming of bimetallic parts.

Effect of hot isostatic pressure on the microstructure and tensile properties of γ'-strengthened superalloy fabricated through induction-assisted directed energy deposition

The microstructure characteristics and strengthening mechanism of Inconel738LC(IN-738LC) alloy prepared by using induction-assisted directed energy deposition(IDED) were elucidated through the investigation of samples subjected to IDED under 1050℃ preheating with and without hot isostatic pressing(HIP,1190℃,105 MPa,and 3 h).Results show that the as-deposited sample mainly consisted of epitaxial columnar crystals and inhomogeneously distributed γ’ phases in interdendritic and dendritic core regions.After HIP,grain morphology changed negligibly,whereas the size of the γ’ phase became increasingly even.After further heat treatment(HT,1070℃,2 h + 845℃,24 h),the γ’ phase in the as-deposited and HIPed samples presented a bimodal size distribution,whereas that in the as-deposited sample showed a size that remained uneven.The comparison of tensile properties revealed that the tensile strength and uniform elongation of the HIP + HTed sample increased by 5% and 46%,respectively,due to the synergistic deformation of bimodal γ’phases,especially large cubic γ’ phases.Finally,the relationship between phase transformations and plastic deformations in the IDEDed sample was discussed on the basis of generalized stability theory in terms of the trade-off between thermodynamics and kinetics.

Revealing precipitation behavior and mechanical response of wire-arc directed energy deposited Mg-Gd-Y-Zr alloy by tailoring aging procedures

Mg-Gd-Y-Zr alloy,as a typical magnesium rare-earth(Mg-RE)alloy,is gaining popularity in the advanced equipment manufacturing fields owing to its noticeable age-hardening properties and high specific strength.However,it is extremely challenging to prepare wrought components with large dimensions and complex shapes because of the poor room-temperature processability of Mg-Gd-Y-Zr alloy.Herein,we report a wire-arc directed energy deposited(DED)Mg-10.45Gd-2.27Y-0.52Zr(wt.%,GW102K)alloy with high RE content presenting a prominent combination of strength and ductility,realized by tailored nanoprecipitates through an optimized heat treatment procedure.Specifically,the solution-treated sample exhibits excellent ductility with an elongation(EL)of(14.6±0.1)%,while the aging-treated sample at 200°C for 58 h achieves an ultra-high ultimate tensile strength(UTS)of(371±1.5)MPa.Besides,the aging-treated sample at 250°C for 16 h attains a good strength-ductility synergy with a UTS of(316±2.1)MPa and a EL of(8.5±0.1)%.Particularly,the evolution mechanisms of precipitation response induced by various aging parameters and deformation behavior caused by nanoprecipitates type were also systematically revealed.The excellent ductility resulted from coordinating localized strains facilitated by active slip activity.And the ultra-high strength should be ascribed to the dense nano-β'hampering dislocation motion.Additionally,the shearable nano-β1 contributed to the good strength-ductility synergy.This work thus offers insightful understanding into the nanoprecipitates manipulation and performance tailoring for the wire-arc DED preparation of large-sized Mg-Gd-Y-Zr components with complex geometries.

Cracking on a nickel-based superalloy fabricated by direct energy deposition

Cracks have consistently been a significant challenge limiting the development of additive manufactured nickel-based superalloys.It is essential to investigate the location of cracks and their forming mechanism.This study extensively examines the impact of solidification process,microstructural evolution,and stress concentration on crack initiation during direct energy deposition(DED).The results emphasize that the crack formation is significantly related to large-angle grain boundaries,rapid cooling rates.Cracks caused by large-angle grain boundaries and a fast-cooling rate predominantly appear near the edge of the deposited samples.Liquation cracks are more likely to form near the top of the deposited sample,due to the presence ofγ/γ'eutectics.The secondary dendritic arm and the carbides in the interdendritic regions can obstruct liquid flow during the final stage of solidification,which results in the formation of solidification cracks and voids.This work paves the way to avoid cracks in nickel-based superalloys fabricated by DED,thereby enhancing the performance of superalloys.

Formation mechanism of inherent spatial heterogeneity of microstructure and mechanical properties of NiTi SMA prepared by laser directed energy deposition

Ni51Ti49 at.%bulk was additively manufactured by laser-directed energy deposition(DED)to reveal the microstructure evolution,phase distribution,and mechanical properties.It is found that the localized remelting,reheating,and heat accumulation during DED leads to the spatial heterogeneous distribution of columnar crystal and equiaxed crystal,a gradient distribution of Ni4Ti3 precipitates along the building direction,and preferential formation of Ni4Ti3 precipitates in the columnar zone.The austenite transformation finish temperature(Af)varies from-12.65℃(Z=33 mm)to 60.35℃(Z=10 mm),corresponding to tensile yield strength(σ0.2)changed from 120±30 MPa to 570±20 MPa,and functional properties changed from shape memory effect to superelasticity at room temperature.The sample in the Z=20.4 mm height has the best plasticity of 9.6%and the best recoverable strain of 4.2%.This work provided insights and guidelines for the spatial characterization of DEDed NiTi.

Effect of wire-arc directed energy deposition on the microstructural formation and age-hardening response of the Mg-9Al-1Zn(AZ91)alloy

In recent years,wire-arc directed energy deposition(wa DED),which is also commonly known as wire-arc additive manufacturing(WAAM),has emerged as a promising new fabrication technique for magnesium alloys.The major reason for this is the possibility of producing parts with a complex geometry as well as a fine-grained microstructure.While the process has been shown to be applicable for Mg-Al-Zn alloys,there is still a lack of knowledge in terms of the influence of the WAAM process on the age-hardening response.Consequently,this study deals with the aging response of a WAAM AZ91 alloy.In order to fully understand the mechanisms during aging,first,the as-built condition was analyzed by means of high-energy X-ray diffraction(HEXRD)and scanning electron microscopy.These investigations revealed a finegrained,equiaxed microstructure with adjacent areas of alternating Al content.Subsequently,the difference between single-and double-step aging as well as conventional and direct aging was studied on the as-built WAAM AZ91 alloy for the first time.The aging response during the various heat treatments was monitored via in situ HEXRD experiments.Corroborating electron microscopy and hardness studies were conducted.The results showed that the application of a double-step aging heat treatment at 325℃with pre-aging at 250℃slightly improves the mechanical properties when compared to the single-step heat treatment at 325℃.However,the hardness decreases considerably after the pre-aging step.Thus,aging at lower temperatures is preferable within the investigated temperature range of 250-325℃.Moreover,no significant difference between the conventionally aged and directly aged samples was found.Lastly,the specimens showed enhanced precipitation kinetics during aging as compared to cast samples.This could be attributed to a higher amount of nucleation sites and the particular temperature profile of the solution heat treatment.

Fundamental Concepts behind the Development of Gamma-Ray, Directed Energy Sources

We discuss novel advanced concepts suitable for the practical design of gamma-ray sources of directed energy. One concept is based on the self-channeling of a powerful optical laser in a gas within a metal tube. Another concept employs a direct excitation of a quadrupole nuclear level by a powerful optical laser. The third concept is based on the process of a high-order harmonic generation by an x-ray laser. All three concepts can be used for designing gamma-ray lasers that would have significant advantages over x-ray lasers. First, missile defense systems employing gamma-ray lasers would be weather independent. Second, the gamma-ray laser radiation can penetrate through the sand, which could be suspended in the air in a desert either naturally (due to strong winds) or artificially (as a protective “shield”). Besides, the first out of the three concepts can beemployed for creating non-laser gamma-ray sources of directed energy to be used for detecting stored radioactive materials, including the radioactive materials carried by an aircraft or a satellite. Last but not least: these concepts can be also used for remotely destroying biological and chemical weapons as a preemptive strike or during its delivery phase, as well as for distinguishing a nuclear warhead from decoy warheads. Thus, the defense capabilities of the proposed gamma-ray lasers can save numerous lives.

Microstructure and mechanical property of additively manufactured NiTi alloys:A comparison between selective laser melting and directed energy deposition

NiTi shape memory alloy(SMA)with nominal composition of Ni 50.8 at%and Ti 49.2 at%was additively manufactured(AM)by selective laser melting(SLM)and laser directed energy deposition(DED)for a comparison study,with emphasis on its phase composition,microstructure,mechanical property and deformation mechanism.The results show that the yield strength and ductility obtained by SLM are 100 MPa and 8%,respectively,which are remarkably different from DED result with 700 MPa and 2%.The load path of SLM sample presents shape memory effect,corresponding to martensite phase detected by XRD;while the load path of DED presents pseudo-elasticity with austenite phase.In SLM sample,fine grain and hole provide a uniform deformation during tensile test,resulting in a better elongation.Furthermore,the nonequilibrium solidification was studied by a temperature field simulation to understand the difference of the two 3D printing methods.Both temperature gradient G and growth rate R determine the microstructure and phase in the SLM sample and DED sample,which leads to similar grain morphologies because of similar G/R.While higher G×R of SLM leads to a finer grain size in SLM sample,providing enough driving force for martensite transition and subsequently changing texture compared to DED sample.

Damage to aircraft composite structures caused by directed energy system: A literature review

This paper presents a comprehensive review of the research studies on direct energy system effect on aircraft composite structures to develop a good understanding of state-of-the-art research and development in this area.The review begins with the application of composite materials in the aircraft structures and highlights their particular areas of application and limitations.An overview of directed energy system is given.Some of the commonly used systems in this category are discussed and the working principles of laser energy systems are described.The experimental and numerical studies reported regarding the aircraft composite structures subject to the effect of directed energy systems,especially the laser systems are reviewed in detail.In particularly,the general effects of laser systems and the relevant damage mechanisms against the composite structures are reported.The review draws attention to the recent research and findings in this field and is expected to guide engineers/researchers in future theoretical,numerical,and experimental studies.

Comparison of the Performance of Two Direct Wave Energy Conversion Systems: Archimedes Wave Swing and Power Buoy

Many wave energy conversion devices have not been well received. The main reasons are that they are too complicated and not economical. However, in the last two decades direct conversion systems have drawn the attention of researchers to their widely distributed energy source due to their simple structure and low cost. The most well-known direct conversion systems presently in use include the Archimedes Wave Swing (AWS) and Power Buoy (PB). In this paper, these two systems were simulated in the same conditions and their behaviors were studied in different wave conditions. In order to verify the simulations, results of the generator of the finite element computations were followed. An attempt was made to determine the merits and drawbacks of each method under different wave conditions by comparing the performance of the two systems. The wave conditions suitable for each system were specified.

Energy-Efficient Transceiver Design for Multi-Pair Two-Way Relay Systems

In this paper, we focus on energy-efficient transceiver and relay beamforming design for multi-pair two-way relay system. The multi-antenna users and the multi-antenna relay are considered in this work. Different from the existing works, the proposed algorithm is energy-efficient which is more applicable to the future green network. It considers both the sum-MSE problem and the power consumption problem for the users under the relay power constraint. Based on the optimal condition decomposition(OCD) method, the energy-efficient precoders at the users can be designed separately with limited information exchanged. The proposed relay beamforming algorithm is based on the alternative direction method of multipliers(ADMM) which has simpler iterative solution and enjoys good convergence. Simulation results demonstrate the performance of the proposed algorithms in terms of power consumption and MSE performance.

Distribution,exploitation,and utilization of intermediate-to-deep geothermal resources in eastern China

The part of China,east of the Hu Huanyong Line,is commonly referred to as eastern China.It is characterized by a high population density and a well-developed economy;it also has huge energy demands.This study assesses and promotes the large-scale development of geothermal resources in eastern China by analyzing deep geological structures,geothermal regimes,and typical geothermal systems.These analyses are based on data collected from geotectology,deep geophysics,geothermics,structural geology,and petrology.Determining the distribution patterns of intermediate-to-deep geothermal resources in the region helps develop prospects for their exploitation and utilization.Eastern China hosts superimposed layers of rocks from three major,global tectonic domainsd namely Paleo-Asian,Circum-Pacific,and Tethyan rocks.The structure of its crust and mantle exhibits a special flyover pattern,with basins and mountains as well as well-spaced uplifts and depressions alternatively on top.The lithosphere in Northeast China and North China is characterized by a thin,low density crust and mantle,whereas the lithosphere in South China has a thin,low density crust and a thick,high density mantle.The middle and upper crust contain geobodies with high conductivity and low velocity,with varying degrees of development that create favorable conditions for the formation and enrichment of geothermal resources.Moderate-to-high temperature geothermal resources are distributed in the MesozoiceCenozoic basins in eastern China,although moderate temperature geothermal resources with low abundance dominate.Porous sandstone reservoirs,karstified fractured-vuggy carbonate reservoirs,and fissured granite reservoirs are the main types of geothermal reservoirs in this region.Under the currently available technical conditions,the exploitation and utilization of geothermal resources in eastern China favor direct utilization over large-scale geothermal power generation.In Northeast China and North China,geothermal resources could be applied for large-scale geothermal heating purposes;geothermal heating could be applied during winter along parts of the Yangtze River while geothermal cooling would be more suitable for summer there;geothermal cooling could also be applied to much of South China.Geothermal resources can also be applied to high value-added industries,to aid agricultural practices,and for tourism.

An experimental study on effects of temperature gradient on microstructure of a 308L stainless steel manufactured by directed energy deposition

The effect of spatial temperature gradient on the microstructural evolution of a 308L stainless steel during the directed energy deposition(DED)process was experimentally investigated.A novel cooling system was designed and incorporated to a DED system in order to control the temperature gradient along the deposition direction during solidification.During deposition,the workpiece was placed on a lifting platform,and as the deposition process proceeded,the platform and workpiece were gradually lowered into cooling water so that the temperature gradient along the deposition direction could be controlled and maintained stable during the deposition process.The microstructure characterization results indicated that a deposition strategy with higher G and G/R values(where G is temperature gradient and R is solidification rate)produced finer cellular grains that were better aligned with the deposition direction,while a deposition strategy with lower G and G/R values produced columnar grains with larger primary arm spacing and less aligned with the deposition direction.

Pore Formation Mechanism in W-C Hard Coatings Using Directed Energy Deposition on Tungsten Alloy

Porosity is a common phenomenon and can significantly hinder the quality of the coating.Here,the pore formation mechanism and the characteristics of the single tracks of the W-C coating using directed energy deposition(DED)are systematically investigated.The forming quality of the tracks,the distribution of the pores,and the elemental distribution near the pores are analyzed by the observations of the cross-sections of the tracks.The temperature field of the melt pool is discussed comprehensively to reveal the pore formation mechanism.The results confirm that Ni and Co evaporated during the DED process due to the high temperature of the melt pool.Pores were continuously produced adjacent to the fusion line when the melt pool was about to solidify since the temperature at the solidification front was higher than the boiling point of Ni.The vaporization area at the fusion line was proposed,where Ni could also evaporate at the time the melt pool started to solidify.The relationship between the solidification rate,the size of the vaporization area and the DED parameters(laser power and scanning speed)was established to discuss the causes of severe pores above the fusion line.This work contains a practical guide to reduce or eliminate the porosity in the coating preparation process on the surface of the tungsten alloy.

High-Superelasticity NiTi Shape Memory Alloy by Directed Energy Deposition-Arc and Solution Heat Treatment

Directed energy deposition-arc(DED-Arc)technology has the advantages of simple equipment,low manufacturing cost and high deposition rate,while the use of DED-Arc has problems of microstructure inhomogeneity,position dependence of macroscopic mechanical properties and anisotropy.Therefore,it is necessary to carry out a subsequent heat treatment to improve its microstructure uniformity,mechanical properties and superelasticity.In this investigation,the DED-Arc 15-layer NiTi alloy thin-walled parts with the solution treatment at different process parameters were studied to analyze the effects of solution heat treatment on microstructure,phase composition,phase transformation,microhardness,tensile and superelasticity.The temperature range of solution treatment is 800-1050℃,and the treatment time range is 1-5.5 h.The results show that after solution treatment at 800℃/1 h,the content of precipitated phase decreases,the grain is refined,the microhardness increases,and the mechanical properties in the 0°direction are improved.The strain recovery rate after 10 tensile cycles has increased from 37.13%(as-built)to 49.25%(solid solution treatment).This research provides an effective post treatment method for high-performance DED-Arc NiTi shape memory alloys.

Effect of Microstructural Characteristics on Fracture Toughness in Direct Energy Deposited Novel Ti-6Al-4V-1Mo Alloy

Meeting the damage tolerance requirements for engineering-grade titanium alloys pose a significant challenge in achieving high fracture toughness in direct energy deposition(DED)titanium alloys.This work primarily investigated the relationship between the microstructure and the fracture toughness of DED new Ti-6Al-4V-1Mo alloy.Two types of microstructures were designed via two process strategies:high-line energy density(HE)and low-line energy density(LE).Relative to LE samples,HE samples possess larger-sized microstructural characteristics(coarser grain boundaryα(α_(GB)),largerαcolonies,and coarserαlaths).Lessα/βphase boundaries were formed by coarserαlaths in the HE samples,increasing the movement of dislocations,resulting in tensile strength decreasing from 1007.1 MPa(LE)to 930.8 MPa(HE)and elongation increasing from 10.8%(LE)to 15.7%(HE).Also,HE samples exhibited an excellent fracture toughness of 114.0 MPa m^(1/2),significantly higher than that of LE samples(76.8 MPa m^(1/2)).An analysis of crack propagation paths was conducted to investigate the factors contributing to toughening.The primary factor enhancing toughness is the frequent obstruction of cracks by coarseαGB and largeαcolonies in HE samples.Particularly,the pretty large-angle deflections induced by the superposition effect of coarseαGB and largeαcolonies play a vital of significant role.These factors induced the long and tortuous high-energy pathways,which resulted in ultimately improved fracture toughness.The discovered microstructural toughening mechanisms can serve as a reference for future studies involving titanium alloys,offering insights on how to enhance fracture toughness by achieving similar characteristics.

Utilizing dual-pathway energy transfer in upconversion nanoconjugates for reinforced photodynamic therapy

Enhancing the therapeutic effect of existing treatments or developing new non-invasive treatments are important measures to achieve high-efficiency treatment of malignant tumors.Photodynamic therapy(PDT)is an emerging treatment modality,and the key for achieving high-efficiency PDT is to select light with strong tissue penetration depth and enhance the generation of reactive oxygen species(ROS).Although the upconversion nanoparticles(UCNPs)modified with the photosensitizers could achieve PDT with strong penetration depth under near-infrared light irradiation,the ROS generated by traditional single-pathway PDT is still insufficient.Herein,we developed a novel nanoconjugate(UCNP-Ce6/AIEgen)for dual-pathway reinforced PDT,in which the UCNPs were co-modified with chlorin e6(Ce6)and luminogen with aggregation-induced emission(AIEgen).Due to the presence of AIEgen,UCNP-Ce6/AIEgen could avoid aggregation-caused luminescence quenching in biological water environments and convert upconversion luminescence(UCL)of UCNPs to Ce6-activatable fluorescence.Therefore,under the irradiation of 808 nm laser,UCNP-Ce6/AIEgen can not only undergo direct lanthanide-triplet energy transfer to activate Ce6,but also convert the UCL of UCNPs to the light that can activate Ce6 through Fӧrster resonance energy transfer to generate more ROS,thus promoting tumor cell apoptosis.This work broadens the applications of nanoconjugates of lanthanide-based inorganic materials and organic dyes,and provides a conception for reinforced PDT of tumors.

CdS Thin Films Deposited by CBD Method on Glass

CdS thin films were prepared by chemical-bath-deposited method and the effect of temperature and time on the properties of CdS thin films was studied. Independent of the deposited temperature, the growth was mainly controlled by the ion-by-ion growth mechanism at the beginning of the film deposition, then the cluster-by-cluster mechanism came to be dominant. The growth rate increased faster with the increasing of temperature until the thickness reached the limitation, then thickness instead become thinner. The scanning electron micro- scope results revealed that the morphology of the CdS film changed from pinholes to rough, inhomogeneous surface with increasing deposition time and deposition temperature. The X- ray diffraction results showed the film structure was a mixture of two phases： hexagonal and cubic, and it was very important to controll deposition time to the film＇s crystal phase. All films in depth of approxilnate 100 nm existed above 65% transmittance, the absorption edge became ＂red-shift＂ with temperature rising. At 60 and 70℃, with 20 min deposited-time, the energy band gap was more than 2.42 eV and decreased with time, while at 80 and 90℃ the energy band gap was less than 2.42 eV and increased little when the time changed from 10min to 15 nfin at 80℃.

Effects of heat treatment on microstructure and mechanical properties of Inconel 625 alloy fabricated by wire arc additive manufacturing process

The microstructure and mechanical properties of Inconel 625 alloy fabricated by wire arc additive manufacturing process were evaluated under as-prepared and heat-treated conditions.A dendritic Ni-based solid solution phase along with(Nb,Ti)C carbide,Laves,and δ-Ni3Nb secondary phases were developed in the microstructure of the as-prepared alloy.Solution heat treatment led to the dissolution of Laves and Ni3Nb phases.In addition,dendrites were replaced with large columnar grains.Aging heat treatment resulted in the formation of grain boundary M23C6 carbide and nanometric γ''precipitates.Hardness,yield and tensile strengths,as well as elongation of the as-prepared part,were close to those of the cast alloy and its fracture occurred in a transgranular ductile mode.Solution heat treatment improved hardness and yield strength and declined the elongation,but it did not have a considerable impact on the tensile strength.Furthermore,aging heat treatment caused the tensile properties to deteriorate and changed the fracture to a mixture of transgranular ductile and intergranular brittle mode.