Alloy design against the solidification cracking in fusion additive manufacturing: an application to a FeCrAl alloy

Published on May 13, 2021in Materials research letters6.6
· DOI :10.1080/21663831.2021.1922945
Bogdan Dovgyy5
Estimated H-index: 5
(Imperial College London),
Marco Simonelli14
Estimated H-index: 14
(University of Nottingham),
Minh-Son Pham14
Estimated H-index: 14
(Imperial College London)
This study developed a design methodology against liquid-state cracking by combining the Scheil–Gulliver solidification simulations and Machine Learning analysis to design alloys for Fusion Additiv...
#1Hui Wang (CSU: Central South University)H-Index: 1
#2Liu ChenH-Index: 74
Last. Minh-Son Pham (Royal School of Mines)H-Index: 14
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Abstract This study analyses literature data to identify optimised print parameters and assesses the consolidation, microstructure, and mechanical properties of Hastelloy-X printed by laser powder bed fusion. Effects of post annealing and hot-isostatic pressing (HIP) on the microstructure and mechanical properties are also revealed. The susceptibility to the solidification cracking was evaluated on the basis the solidification gradient and freezing range obtained via the calculation of thermodyn...
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#1Richard J. Williams (Imperial College London)H-Index: 4
#2Jalal Al-Lami (Imperial College London)H-Index: 1
Last. Catrin M. Davies (Imperial College London)H-Index: 23
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Abstract 316 L stainless steel has long been used in high temperature applications. As a well-established laser powder bed fusion (LPBF) alloy, there are opportunities to utilise additive manufacturing in such applications. However, the creep behaviour of LPBF 316 L under multiaxial stress conditions must first be quantified before such opportunities are realised. Uniaxial and double notched bar creep tests have been performed and characterised using power-law relations to evaluate the creep str...
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#1Yining He (CMU: Carnegie Mellon University)H-Index: 3
#2Ming Zhong (CMU: Carnegie Mellon University)H-Index: 1
Last. Bryan A. Webler (CMU: Carnegie Mellon University)H-Index: 9
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Abstract This study investigated laser powder bed fusion (LPBF) additive manufacturing of H13 tool steel to identify how laser power (P) and scan speed (V) influenced melt pool geometry, microstructure, and susceptibility to cracking. Sequential studies from tracks, pads to 3D cubes were performed. Tracks and pads were made by laser scan on H13 build plates with and without powder addition. P-V windows were identified where keyholing, balling and under-melt occurred. The only change in melt pool...
8 CitationsSource
#1Bogdan Dovgyy (Imperial College London)H-Index: 5
#2Alessandro Piglione (Imperial College London)H-Index: 5
Last. Minh-Son Pham (Imperial College London)H-Index: 14
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Abstract This study assesses the printability including the consolidation, solidification microstructure, and mechanical properties of the CoCrFeMnNi high entropy alloy fabricated by Laser Powder Bed Fusion. A range of print parameters was used for a comprehensive assessment of printability, providing a basis to establish the relationship between process, microstructure, and mechanical properties. The study demonstrates a high relative density of the alloy fabricated with energy density in the r...
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#1João Pedro Oliveira (NOVA: Universidade Nova de Lisboa)H-Index: 49
#2A.D. LaLonde (Booz Allen Hamilton)H-Index: 1
Last. Ji Ma (UVA: University of Virginia)H-Index: 21
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Abstract As metallic additive manufacturing grew in sophistication, users have requested greater control over the systems such as the ability to change the process parameters. The goal of this manuscript is to review the effects of major process parameters on build quality (porosity, residual stress, and composition changes) and materials properties (microstructure and microsegregation), and to serve as a guide on how these parameters may be modified to achieve specific design goals for a given ...
126 CitationsSource
#1Minh-Son Pham (Imperial College London)H-Index: 14
#2Bogdan Dovgyy (Imperial College London)H-Index: 5
Last. Alessandro Piglione (Imperial College London)H-Index: 5
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In-depth understanding of microstructure development is required to fabricate high quality products by additive manufacturing (for example, 3D printing). Here we report the governing role of side-branching in the microstructure development of alloys by laser powder bed fusion. We show that perturbations on the sides of cells (or dendrites) facilitate crystals to change growth direction by side-branching along orthogonal directions in response to changes in local heat flux. While the continuous e...
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#1Andrew T. Polonsky (UCSB: University of California, Santa Barbara)H-Index: 7
#2William C. Lenthe (UCSB: University of California, Santa Barbara)H-Index: 16
Last. Tresa M. Pollock (UCSB: University of California, Santa Barbara)H-Index: 70
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Abstract A sample of 304L stainless steel manufactured by Laser Engineered Net Shaping (LENS) was characterized in 3D using TriBeam tomography. The crystallographic, structural, and chemical properties of the as-deposited microstructure have been studied in detail. 3D characterization reveals complex grain morphologies and large orientation gradients, in excess of 10∘, that are not easily interpreted from 2D cross-sections alone. Misorientations were calculated via a methodology that locates the...
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#1Dierk Raabe (MPG: Max Planck Society)H-Index: 134
#2Cemal Cem Tasan (MIT: Massachusetts Institute of Technology)H-Index: 37
Last. Elsa Olivetti (MIT: Massachusetts Institute of Technology)H-Index: 26
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Metallic materials have enabled technological progress over thousands of years. The accelerated demand for structural (that is, load-bearing) alloys in key sectors such as energy, construction, safety and transportation is resulting in predicted production growth rates of up to 200 per cent until 2050. Yet most of these materials require a lot of energy when extracted and manufactured and these processes emit large amounts of greenhouse gases and pollution. Here we review methods of improving th...
60 CitationsSource
#1Xiaoqing NiH-Index: 15
#2Decheng Kong (USTB: University of Science and Technology Beijing)H-Index: 17
Last. Wenheng WuH-Index: 4
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Mechanical properties of Hastelloy X alloys fabricated by selective laser melting were investigated and compared with the wrought counterpart. Nano-inclusions (Mo-rich carbides) distributed at the sub-grain boundaries in the selective laser-melted (SLMed) Hastelloy X alloy, whereas micron-scale precipitations existed in the wrought counterpart. The molten pool boundaries widely existed in the SLMed substrate, which acted as an initial site for crack and led to poor plasticity. However, the ultim...
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#1Morgan LetenneurH-Index: 3
#2Alena KreitcbergH-Index: 10
Last. Vladimir BrailovskiH-Index: 32
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A simplified analytical model of the laser powder bed fusion (LPBF) process was used to develop a novel density prediction approach that can be adapted for any given powder feedstock and LPBF system. First, calibration coupons were built using IN625, Ti64 and Fe powders and a specific LPBF system. These coupons were manufactured using the predetermined ranges of laser power, scanning speed, hatching space, and layer thickness, and their densities were measured using conventional material charact...
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Cited By1
#1Benjamin WahlmannH-Index: 1
Last. Carolin KörnerH-Index: 55
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In this work, we investigated the viability of established hot cracking models for numerically based development of crack-resistant nickel-base superalloys with a high γ′ volume fraction for additive manufacturing. Four cracking models were implemented, and one alloy designed for reduced cracking susceptibility was deduced based on each cracking criterion. The criteria were modeled using CALPHAD-based Scheil calculations. The alloys were designed using a previously developed multi-criteria optim...