INFLUENCE OF CEO2 ADDITION AND SCANNING SPEED ON MICROSTRUCTURE AND TRIBOLOGICAL BEHAVIOR OF LASER-CLAD Ti-Co REINFORCED COATINGS ON Ti-6Al-4V ALLOY

2019 ◽  
Vol 27 (04) ◽  
pp. 1950129
Author(s):  
O. S. ADESINA ◽  
G. A. FAROTADE ◽  
A. P. I. POPOOLA ◽  
D. T. OLORUNTOBA
Keyword(s):  
Gas Flow ◽  
Tribological Behavior ◽  
Surface Hardness ◽  
Wear Test ◽  
Rare Earth Oxide ◽  
Scanning Speed ◽  
Spot Size ◽  
Melt Pool ◽  
Scan Speed ◽  
Set Up

Ti-6Al-4V alloy is restricted in industrial application as a result of its relatively low hardness and poor tribological properties. However, the limitations associated with Ti-6Al-4V in severe tribological conditions can be improved via laser cladding technique. In this study, the influence of rare earth oxide (CeO[Formula: see text] addition on microstructure, hardness and tribological behavior of laser-clad titanium–cobalt-based coatings on Ti6Al4V alloy was investigated. The optimized parameters used for laser depositions are laser power 900[Formula: see text]W; beam spot size 3[Formula: see text]mm; powder feed rate 1.0[Formula: see text]g/min; gas flow rate 1.2[Formula: see text]L/min while laser scan speed was varied at 0.6[Formula: see text]m/min and 1.2[Formula: see text]m/min. Thereafter, the coating morphology as well as wear mechanism of the coatings of CeO2 particles (5–10[Formula: see text]wt.%) dispersed in TiCo matrix were investigated via scanning electron microscope (SEM) equipped with energy dispersed spectrometry (EDS), whereas the intermetallic phases present in the coatings were observed using Philips PW1713 X-ray diffractometer (XRD). Furthermore, the micro-hardness values of the coatings were recorded while wear test was carried out using a reciprocating set up (UMT-2 — CETR tribometer). Results revealed that the incorporation of CeO2 particles into the melt pool influenced the morphology of the coatings, thus resulting in finer cellular dendrites, homogenous and strong metallurgical bonding between the laser cladded coating and the substrate. The phases revealed various fractions of interdendritic compounds (CeCo2, Ni3Ti, Co2Ti, CoTi, Al2O3, TiO, AlTi3, and Ce2O[Formula: see text] dispersed within the coating matrix, thus resulting in 2.68 times improvement on the surface hardness and 47.4% reduction in friction coefficient in comparison with Ti-6Al-4V alloy.

scholarly journals Parametric Study on In Situ Laser Powder Bed Fusion of Mo(Si1−x,Alx)2

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4849
Author(s):  
T. Minasyan ◽  
S. Aydinyan ◽  
E. Toyserkani ◽  
I. Hussainova
Keyword(s):  
Parametric Study ◽  
Laser Power ◽  
Side Surface ◽  
Scanning Speed ◽  
Processing Parameters ◽  
Powder Bed ◽  
Good Surface ◽  
Melt Pool ◽  
Scan Speed ◽  
Good Surface Finish

Mo(Si1−x,Alx)2 composites were produced by a pulsed laser reactive selective laser melting of MoSi2 and 30 wt.% AlSi10Mg powder mixture. The parametric study, altering the laser power between 100 and 300 W and scan speed between 400 and 1500 mm·s−1, has been conducted to estimate the effect of processing parameters on printed coupon samples’ quality. It was shown that samples prepared at 150–200 W laser power and 400–500 mm·s−1 scan speed, as well as 250 W laser power along with 700 mm·s−1 scan speed, provide a relatively good surface finish with 6.5 ± 0.5 µm–10.3 ± 0.8 µm roughness at the top of coupons, and 9.3 ± 0.7 µm–13.2 ± 1.1 µm side surface roughness in addition to a remarkable chemical and microstructural homogeneity. An increase in the laser power and a decrease in the scan speed led to an apparent improvement in the densification behavior resulting in printed coupons of up to 99.8% relative density and hardness of ~600 HV1 or ~560 HV5. The printed parts are composed of epitaxially grown columnar dendritic melt pool cores and coarser dendrites beyond the morphological transition zone in overlapped regions. An increase in the scanning speed at a fixed laser power and a decrease in the power at a fixed scan speed prohibited the complete single displacement reaction between MoSi2 and aluminum, leading to unreacted MoSi2 and Al lean hexagonal Mo(Si1−x,Alx)2 phase.

scholarly journals Frequency domain measurements of melt pool recoil force using modal analysis

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Tristan Cullom ◽  
Cody Lough ◽  
Nicholas Altese ◽  
Douglas Bristow ◽  
Robert Landers ◽  
...  
Keyword(s):  
High Speed ◽  
Process Development ◽  
Critical Factor ◽  
Spot Size ◽  
Recoil Pressure ◽  
Powder Bed ◽  
Melt Pool ◽  
Recoil Force ◽  
Scan Speed ◽  
Synchrotron Imaging

AbstractRecoil pressure is a critical factor affecting the melt pool dynamics during Laser Powder Bed Fusion (LPBF) processes. Recoil pressure depresses the melt pool. When the recoil pressure is low, thermal conduction and capillary forces may be inadequate to provide proper fusion between layers. However, excessive recoil pressure can produce a keyhole inside the melt pool, which is associated with gas porosity. Direct recoil pressure measurements are challenging because it is localized over an area proportionate to the laser spot size producing a force in the mN range. This paper reports a vibration-based approach to quantify the recoil force exerted on a part in a commercial LPBF machine. The measured recoil force is consistent with estimates from high speed synchrotron imaging of entrained particles, and the results show that the recoil force scales with applied laser power and is inversely related to the laser scan speed. These results facilitate further studies of melt pool dynamics and have the potential to aid process development for new materials.

scholarly journals Frequency Domain Measurements of Melt Pool Recoil Force Using Modal Analysis

2020 ◽  
Author(s):  
Tristan Cullom ◽  
Cody Lough ◽  
Nicholas Altese ◽  
Douglas Bristow ◽  
Robert Landers ◽  
...  
Keyword(s):  
High Speed ◽  
Process Development ◽  
Critical Factor ◽  
Spot Size ◽  
Recoil Pressure ◽  
Powder Bed ◽  
Melt Pool ◽  
Recoil Force ◽  
Scan Speed ◽  
Synchrotron Imaging

Abstract Recoil pressure is a critical factor affecting the melt pool dynamics during Laser Powder Bed Fusion (LPBF) processes. Recoil pressure depresses the melt pool, providing layer-to-layer fusion without introducing porosity. If the recoil pressure is too low, the process operates in a conduction mode where layers will not properly fuse, while excessive recoil pressure leads to a keyhole mode, which results in gas porosity. Direct recoil pressure measurements are challenging because it is localized over an area proportionate to the laser spot size producing a force in the mN range. This paper reports a vibration-based approach to quantify the recoil force exerted on a part in a commercial LPBF machine. The measured recoil force is consistent with estimates from high speed synchrotron imaging of entrained particles, and the results show that the recoil force scales with applied laser power and is inversely related to the laser scan speed. These results facilitate further studies of melt pool dynamics and have the potential to aid process development for new materials.

A STUDY ON SCAN SPEED RELATIONSHIP WITH MICROSTRUCTURAL EVOLUTION, PHASE COMPOSITION AND MICROHARDNESS OF Ni-CONTAINING INTERMETALLIC COATINGS ON Ti–6Al–4V USING LASER CLADDING TECHNIQUE

2018 ◽  
Vol 25 (08) ◽  
pp. 1950035 ◽  
Author(s):  
O. S. ADESINA ◽  
A. P. I. POPOOLA ◽  
S. L. PITYANA ◽  
D. T. OLORUNTOBA
Keyword(s):  
Laser Cladding ◽  
Laser Scanning ◽  
Gas Flow ◽  
Microstructural Analysis ◽  
Scanning Speed ◽  
Metallurgical Bonding ◽  
Clad Layer ◽  
Fine Microstructure ◽  
Scan Speed ◽  
Laser Scanning Speed

Titanium alloys have been used for variety of engineering applications but their relatively low hardness and low thermal conductivity are shortcomings that have reduced their potential use. In this work, attempts have been made to study the effects of laser scanning speed and admixed fraction of reinforced Ni–Co powders on clad layer formation and its corresponding properties on Ti–6Al–4V. Laser power of 750[Formula: see text]W, beam size of 3[Formula: see text]mm with argon shield gas flow rate of 1.2[Formula: see text]L/min was made constant, while the powders were premixed and deposited on Ti–6Al–4V with varying compositions at different scanning speeds of 0.6 and 1.2[Formula: see text]m/min. The microstructural analysis, phase constituents and hardness properties of Ni–Co intermetallics reinforced clads were also examined. The morphology of the resultant coatings was analyzed using X-ray diffractometry (XRD) and scanning electron microscopy (SEM) equipped with energy dispersive spectrometry (EDS). The research results showed that laser cladding coatings displayed enhanced properties such as fine microstructure and good metallurgical bonding with the substrate containing minimal pores with respect to the substrate. Furthermore, the microstructure revealed the formation of various fractions of interdendritic compounds/intermetallics dispersed within the coating matrix which could be responsible for the increased hardness obtained. The average hardness of the coating was about 856[Formula: see text]HV [Formula: see text], which was about 2.5 times that of the substrate.

Laser Re-Melt Technique for Laser Additive Repair of Narrow Rectangular Cracks in Grade 5 Titanium Alloy (Ti-6Al-4V)

2019 ◽  
Vol 796 ◽  
pp. 129-136
Author(s):  
Tawanda Marazani ◽  
Daniel Makundwaneyi Madyira ◽  
Esther Titilayo Akinlabi
Keyword(s):  
Gas Flow ◽  
Focal Length ◽  
Scanning Speed ◽  
Spot Size ◽  
Additive Technology ◽  
Rectangular Crack ◽  
Grade 5 ◽  
Crack Repair ◽  
Repair Attempts ◽  
Size Powder

Groove inaccessibility, top groove powder impedance, irregular sidewall powder delivery and lack of sidewall vertical irradiation have been reported as major limitations for the use of Laser Additive Technology (LAT) for narrow rectangular crack repair applications. As a result, most reported repair attempts were concluded unsuccessful. In the present work, a multi-track laser re-melt technique was developed for the repair of narrow rectangular cracks of sizes 2 and 3 mm, both 5 mm deep on 7 mm thick Ti-6Al-4V plates. The laser re-melt technique was carried out at controlled laser power, focal length, spot size, powder feed rate, gas flow rate and scanning speed. The repaired substrates were evaluated for defects through optical microscopy (OM) and scanning electron microscopy (SEM). The obtained results showed densely fused defect-free repaired substrates with good evolving microstructure.

scholarly journals In-Line Analysis of Diffusion Processes in Micro Channels by Long Distance Raman Photometric Measurement Technology—A Proof of Concept Study

Micromachines ◽  
2021 ◽  
Vol 12 (2) ◽  
pp. 116
Author(s):  
Julian Deuerling ◽  
Shaun Keck ◽  
Inasya Moelyadi ◽  
Jens-Uwe Repke ◽  
Matthias Rädle
Keyword(s):  
Numerical Aperture ◽  
Spot Size ◽  
Measuring System ◽  
Optical Systems ◽  
Measurement Technology ◽  
Long Distance ◽  
Measuring Point ◽  
Acetone Concentration ◽  
Micro Channels ◽  
Set Up

This work presents a novel method for the non-invasive, in-line monitoring of mixing processes in microchannels using the Raman photometric technique. The measuring set-up distinguishes itself from other works in this field by utilizing recent state-of-the-art customized photon multiplier (CPM) detectors, bypassing the use of a spectrometer. This addresses the limiting factor of integration times by achieving measuring rates of 10 ms. The method was validated using the ternary system of toluene–water–acetone. The optical measuring system consists of two functional units: the coaxial Raman probe optimized for excitation at a laser wavelength of 532 nm and the photometric detector centered around the CPMs. The spot size of the focused laser is a defining factor of the spatial resolution of the set-up. The depth of focus is measured at approx. 85 µm with a spot size of approx. 45 µm, while still maintaining a relatively high numerical aperture of 0.42, the latter of which is also critical for coaxial detection of inelastically scattered photons. The working distance in this set-up is 20 mm. The microchannel is a T-junction mixer with a square cross section of 500 by 500 µm, a hydraulic diameter of 500 µm and 70 mm channel length. The extraction of acetone from toluene into water is tracked at an initial concentration of 25% as a function of flow rate and accordingly residence time. The investigated flow rates ranged from 0.1 mL/min to 0.006 mL/min. The residence times from the T-junction to the measuring point varies from 1.5 to 25 s. At 0.006 mL/min a constant acetone concentration of approx. 12.6% was measured, indicating that the mixing process reached the equilibrium of the system at approx. 12.5%. For prototype benchmarking, comparative measurements were carried out with a commercially available Raman spectrometer (RXN1, Kaiser Optical Systems, Ann Arbor, MI, USA). Count rates of the spectrophotometer surpassed those of the spectrometer by at least one order of magnitude at identical target concentrations and optical power output. The experimental data demonstrate the suitability and potential of the new measuring system to detect locally and time-resolved concentration profiles in moving fluids while avoiding external influence.

scholarly journals A Comparative Analysis of Laser Additive Manufacturing of High Layer Thickness Pure Ti and Inconel 718 Alloy Materials Using Finite Element Method

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 876 ◽  
Author(s):  
Sapam Ningthemba Singh ◽  
Sohini Chowdhury ◽  
Yadaiah Nirsanametla ◽  
Anil Kumar Deepati ◽  
Chander Prakash ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Layer Thickness ◽  
Inconel 718 ◽  
Laser Power ◽  
Scanning Speed ◽  
Laser Additive Manufacturing ◽  
Inconel 718 Alloy ◽  
Melt Pool ◽  
High Layer

Investigation of the selective laser melting (SLM) process, using finite element method, to understand the influences of laser power and scanning speed on the heat flow and melt-pool dimensions is a challenging task. Most of the existing studies are focused on the study of thin layer thickness and comparative study of same materials under different manufacturing conditions. The present work is focused on comparative analysis of thermal cycles and complex melt-pool behavior of a high layer thickness multi-layer laser additive manufacturing (LAM) of pure Titanium (Ti) and Inconel 718. A transient 3D finite-element model is developed to perform a quantitative comparative study on two materials to examine the temperature distribution and disparities in melt-pool behaviours under similar processing conditions. It is observed that the layers are properly melted and sintered for the considered process parameters. The temperature and melt-pool increases as laser power move in the same layer and when new layers are added. The same is observed when the laser power increases, and opposite is observed for increasing scanning speed while keeping other parameters constant. It is also found that Inconel 718 alloy has a higher maximum temperature than Ti material for the same process parameter and hence higher melt-pool dimensions.

scholarly journals Optimization of Laser Powder Bed Fusion Processing Using a Combination of Melt Pool Modeling and Design of Experiment Approaches: Density Control

2019 ◽  
Vol 3 (1) ◽  
pp. 21 ◽  
Author(s):  
Morgan Letenneur ◽  
Alena Kreitcberg ◽  
Vladimir Brailovski
Keyword(s):  
Scanning Speed ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Density Prediction ◽  
Melt Pool ◽  
Density Control ◽  
Pool Model ◽  
Conventional Material ◽  
Prediction Approach

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 characterization techniques. Next, a simplified melt pool model was used to calculate the melt pool dimensions for the selected sets of printing parameters. Both sets of data were then combined to predict the density of printed parts. This approach was additionally validated using the literature data on AlSi10Mg and 316L alloys, thus demonstrating that it can reliably be used to optimize the laser powder bed metal fusion process.

Numerical Study of Methane and Air Combustion Inside Heat-Recirculating Combustors

2013 ◽  
Author(s):  
Yanxia Li ◽  
Zhongliang Liu ◽  
Yan Wang ◽  
Jiaming Liu
Keyword(s):  
Gas Flow ◽  
Numerical Study ◽  
Convection Heat Transfer ◽  
Central Area ◽  
Small Scale ◽  
Inlet Velocity ◽  
Strong Convection ◽  
Simulation Results ◽  
Lean Fuel ◽  
Set Up

A numerical model on methane/air combustion inside a small Swiss-roll combustor was set up to investigate the flame position of small-scale combustion. The simulation results show that the combustion flame could be maintained in the central area of the combustor only when the speed and equivalence ratio are all within a narrow and specific range. For high inlet velocity, the combustion could be sustained stably even with a very lean fuel and the flame always stayed at the first corner of reactant channel because of the strong convection heat transfer and preheating. For low inlet velocity, small amounts of fuel could combust stably in the central area of the combustor, because heat was appropriately transferred from the gas to the inlet mixture. Whereas, for the low premixed gas flow, only in certain conditions (Φ = 0.8 ～ 1.2 when ν0 = 1.0m/s, Φ = 1.0 when ν0 = 0.5m/s) the small-scale combustion could be maintained.

Linear and Nonlinear Analysis of Additively Manufactured Material With Different Porosity Induced by Varying Material Printing Speed Using Guided Acoustic Waves

2021 ◽  
Author(s):  
SeHyuk Park ◽  
Hamad Alnuaimi ◽  
Anna Hayes ◽  
Madison Sitkiewicz ◽  
Umar Amjad ◽  
...  
Keyword(s):  
Acoustic Wave ◽  
Nonlinear Analysis ◽  
Lead Zirconate Titanate ◽  
Acoustic Waves ◽  
Scanning Speed ◽  
Lead Zirconate ◽  
Nonlinear Ultrasonic ◽  
Scan Speed ◽  
Linear And Nonlinear ◽  
Characterization Of Materials

Abstract Guided acoustic wave based techniques have been found to be very effective for damage detection, and both quantitative and qualitative characterization of materials. In this research, guided acoustic wave techniques are used for porosity evaluation of additively manufactured materials. A metal 3D printer, Concept Laser Mlab 200 R Cusing™, is used to manufacture 316L additively manufactured (AM) stainless steel specimens. Two levels of porosity are investigated in this study, which was controlled by a suitable combination of scan speed and laser power. The sample with lower level of porosity is obtained with a low scanning speed. Lead Zirconate Titanate (PZT) transducers are used to generate guided acoustic waves. The signal is excited and propagated through the specimens in a single sided transmission mode setup. Signal processing of the recorded signals for damage analysis involves both linear and nonlinear analyses. Linear ultrasonic parameters such as the time-of-flight and magnitude of the propagating waves are recorded. The nonlinear ultrasonic parameter, the Sideband Peak Count Index (SPC-I) is obtained by a newly developed nonlinear analysis technique. Results obtained for both specimens are analyzed and compared using both linear and nonlinear ultrasonic techniques. Finally, the effectiveness of SPC-I technique in monitoring porosity levels in AM specimens is discussed.

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