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...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.展开更多
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...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.展开更多
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 mainstrea...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.展开更多
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 s...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.展开更多
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,reheat...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.展开更多
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 rea...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.展开更多
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 emph...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.展开更多
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 depositio...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.展开更多
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 design...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.展开更多
在冷金属过渡(cold metal transfer,CMT)电弧增材制造过程中,熔池的流动行为极易受到电弧和熔滴的影响,从而严重影响堆积层的稳定性和成形件质量.该文利用高速摄影结果及电信号参数波形图,引入热输入量计算公式,从特征电信号、熔滴过渡...在冷金属过渡(cold metal transfer,CMT)电弧增材制造过程中,熔池的流动行为极易受到电弧和熔滴的影响,从而严重影响堆积层的稳定性和成形件质量.该文利用高速摄影结果及电信号参数波形图,引入热输入量计算公式,从特征电信号、熔滴过渡特征量、热输入量等方面定量分析了CMT+P模式下送丝速度及脉冲修正系数对熔滴过渡过程及单道成形形貌的影响,同时分析了脉冲变极性冷金属过渡(Advanced CMT,CMT+PA)模式下送丝速度及控制面板上的EP/EN修正系数η对熔滴过渡过程及单道成形形貌的影响,为后续工艺优化提供参考和指导.展开更多
基金supported by the National Natural Science Foundation of China(51975112,52375412)Fundamental Research Funds for Central Universities(N2203011)。
文摘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.
基金financial support of the National Natural Science Foundation of China(Nos.52130110 and U22A20189)the Research Fund of the State Key Laboratory of Solidification Processing(No.2023-TS-10)。
文摘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.
基金supported by the 2022 MTC Young Individual Research Grants(Grant No.M22K3c0097)the Singapore Research,Innovation and Enterprise(RIE)2025 PlanSingapore Aerospace Programme Cycle 16(Grant No.M2215a0073)。
文摘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.
基金the financial support by the Defense Industrial Technology Development Program(No.JCKY2020130C024)the National Science and Technology Major Project,China(No.Y2019-Ⅶ-0011-0151)the Science Center for Gas Turbine Project(No.P2022-C-Ⅳ-002-001)。
文摘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.
基金the financial support of the Hunan Innovation Platform and Talent Plan(2022RC3033)Natural Science Foundation of Shandong Province(ZR2020ZD04)Ganzhou Science and Technology Planning Project(Grant No.Ganshikefa[2019]60)。
文摘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.
基金supported by the project CALIPSOplus under the Grant Agreement 730872 from the EU Framework Programme for Research and Innovation HORIZON 2020the financial support of the European Research Council(ERC)under the European Union’s Horizon 2020 research and innovation program(Grant No.771146 TOUGHIT)funded within the AIT’s strategic research portfolio 2022 and by the European Commission within the framework INTERREG V-A Austria–Czech Republic in the project“ReMaP“(Interreg project no.ATCZ229)。
文摘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.
基金Project(2020JJ2046)supported by the Science Fund for Hunan Distinguished Young Scholars,ChinaProject(S2020GXKJGG0416)supported by the Special Project for Hunan Innovative Province Construction,China+1 种基金Project(2018RS3007)supported by the Huxiang Young Talents,ChinaProject(GuikeAB19050002)supported by the Science Project of Guangxi,China。
文摘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.
文摘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.
基金This work was supported by National Key R&D Program of China(Grant No.2022YFB4601000).
文摘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.
文摘在冷金属过渡(cold metal transfer,CMT)电弧增材制造过程中,熔池的流动行为极易受到电弧和熔滴的影响,从而严重影响堆积层的稳定性和成形件质量.该文利用高速摄影结果及电信号参数波形图,引入热输入量计算公式,从特征电信号、熔滴过渡特征量、热输入量等方面定量分析了CMT+P模式下送丝速度及脉冲修正系数对熔滴过渡过程及单道成形形貌的影响,同时分析了脉冲变极性冷金属过渡(Advanced CMT,CMT+PA)模式下送丝速度及控制面板上的EP/EN修正系数η对熔滴过渡过程及单道成形形貌的影响,为后续工艺优化提供参考和指导.