scholarly journals Mechanical and thermal performance of additively manufactured copper, silver and copper–silver alloys

2021 ◽  
pp. 146442072110409
Author(s):  
John Robinson ◽  
Arun Arjunan ◽  
Ahmad Baroutaji ◽  
Mark Stanford
Keyword(s):  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Thermal Performance ◽  
Mechanical Performance ◽  
Three Dimensional ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Three Dimensional Printing ◽  
Industry Standard

On-demand additive manufacturing (three-dimensional printing) offers great potential for the development of functional materials for the next generation of energy-efficient devices. In particular, novel materials suitable for efficient dissipation of localised heat fluxes and non-uniform thermal loads with superior mechanical performance are critical for the accelerated development of future automotive, aerospace and renewable energy technologies. In this regard, this study reports the laser powder bed fusion processing of high purity (>99%) copper (Cu), silver (Ag) and novel copper–silver (CuAg) alloys ready for on-demand additive manufacturing. The processed materials were experimentally analysed for their relative density, mechanical and thermal performance using X-ray computed tomography, destructive tensile testing and laser flash apparatus, respectively. It was found that while Ag featured higher failure strains, Cu in comparison showed a 109%, 17% and 59% improvement in yield strength ([Formula: see text]), Young’s modulus ( E) and ultimate tensile strength, respectively. As such the [Formula: see text], E and ultimate tensile strength for laser powder bed fusion Cu is comparable to commercially available laser powder bed fusion Cu materials. CuAg alloys, however, significantly outperformed Ag, Cu and all commercial Cu materials when it came to mechanical performance offering significantly superior performance. The [Formula: see text], E and ultimate tensile strength for the novel CuAg composition were 105%, 33% and 94% higher in comparison to Cu. Although slightly different, the trend continued with a 106% and 91% rise for [Formula: see text] and ultimate tensile strength, respectively, for CuAg in comparison to industry-standard Cu. Unfortunately, E values for industry-standard Cu alloys were not available. When it came to thermal performance, laser powder bed fusion Ag was found to offer a 70% higher thermal diffusivity in comparison to Cu despite the variation in density and porosity. CuAg alloys however only showed a 0.8% variation in thermal performance despite a 10–30% increase in Ag. Overall, the study presents a new understanding regarding the three-dimensional printing and performance of Cu, Ag and CuAg alloys.

scholarly journals Microstructure and Mechanical Properties of AlSi12CuNi Alloy Fabricated by Laser Powder Bed Fusion Process

2021 ◽  
Vol 15 (4) ◽  
pp. 388-395
Author(s):  
Akihiro Hirayama ◽  
Masaaki Kimura ◽  
Masahiro Kusaka ◽  
Koichi Kaizu ◽  
◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Ultimate Tensile Strength ◽  
Die Casting ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Breaking Elongation ◽  
Microstructure And Mechanical Properties ◽  
Moving Direction

The microstructure and mechanical properties of the AlSi12CuNi alloy fabricated by the additive manufacturing technique, laser powder bed fusion (L-PBF), were investigated. Several laser irradiation conditions were examined to optimize the manufacturing process to obtain a high volume density of the fabricated alloy. Good fabricated samples with a relative density of 99% or higher were obtained with no cracks. The fabricated samples exhibited significantly good mechanical properties, such as ultimate tensile strength, breaking elongation, and micro-hardness, compared to the conventional die casting AlSi12CuNi alloy. Fine microstructures consisting of the α-Al phase and a nano-sized eutectic Al-Si network were observed. The dimensions of the microstructures were smaller than those of the conventional die-casting AlSi12CuNi alloy. The superior mechanical properties were attributed to the microstructure associated with the rapid solidification in the L-PBF process. Furthermore, the influence of the building direction on the mechanical properties of the fabricated samples was evaluated. The ultimate tensile strength and breaking elongation were significantly affected by the building direction; mechanical properties parallel to the roller moving direction were significantly better than those perpendicular to the roller moving direction. In conclusion, AlSi12CuNi alloys with good characteristics were successfully fabricated by the L-PBF process.

scholarly journals Optimization of the Post-Process Heat Treatment of Inconel 718 Superalloy Fabricated by Laser Powder Bed Fusion Process

Metals ◽  
2021 ◽  
Vol 11 (1) ◽  
pp. 144
Author(s):  
Eslam M. Fayed ◽  
Mohammad Saadati ◽  
Davood Shahriari ◽  
Vladimir Brailovski ◽  
Mohammad Jahazi ◽  
...  
Keyword(s):  
Inconel 718 ◽  
Mechanical Performance ◽  
Solution Treatment ◽  
Heat Treatments ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Homogenization Treatment ◽  
Powder Bed ◽  
Post Process ◽  
High Fraction

In the present study, multi-objective optimization is employed to develop the optimum heat treatments that can achieve both high-mechanical performance and non-distinctive crystallographic texture of 3D printed Inconel 718 (IN718) fabricated by laser powder bed fusion (LPBF). Heat treatments including homogenization at different soaking times (2, 2.5, 3, 3.5 and 4 h) at 1080 °C, followed by a 1 h solution treatment at 980 °C and the standard aging have been employed. 2.5 h is found to be the homogenization treatment threshold after which there is a depletion of hardening precipitate constituents (Nb and Ti) from the γ-matrix. However, a significant number of columnar grains with a high fraction (37.8%) of low-angle grain boundaries (LAGBs) have still been retained after the 2.5 h homogenization treatment. After a 4 h homogenization treatment, a fully recrystallized IN718 with a high fraction of annealing twins (87.1%) is obtained. 2.5 and 4 h homogenization treatments result in tensile properties exceeding those of the wrought IN718 at both RT and 650 °C. However, considering the texture requirements, it is found that the 4 h homogenization treatment offers the optimum treatment, which can be used to produce IN718 components offering a balanced combination of high mechanical properties and adequate microstructural isotropy.

scholarly journals Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

Metals ◽  
2020 ◽  
Vol 10 (3) ◽  
pp. 341 ◽  
Author(s):  
Eleonora Santecchia ◽  
Stefano Spigarelli ◽  
Marcello Cabibbo
Keyword(s):  
Additive Manufacturing ◽  
Side Effects ◽  
Metal Powder ◽  
Three Dimensional ◽  
High Energy ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Metal Additive Manufacturing ◽  
Metal Additive

Metal additive manufacturing is changing the way in which engineers and designers model the production of three-dimensional (3D) objects, with rapid growth seen in recent years. Laser powder bed fusion (LPBF) is the most used metal additive manufacturing technique, and it is based on the efficient interaction between a high-energy laser and a metal powder feedstock. To make LPBF more cost-efficient and environmentally friendly, it is of paramount importance to recycle (reuse) the unfused powder from a build job. However, since the laser–powder interaction involves complex physics phenomena and generates by-products which might affect the integrity of the feedstock and the final build part, a better understanding of the overall process should be attained. The present review paper is focused on the clarification of the interaction between laser and metal powder, with a strong focus on its side effects.

scholarly journals Increasing the productivity of laser powder bed fusion: Influence of the hull-bulk strategy on part quality, microstructure and mechanical performance of Ti-6Al-4V

2020 ◽  
Vol 33 ◽  
pp. 101129 ◽  
Author(s):  
Charlotte de Formanoir ◽  
Umberto Paggi ◽  
Thomas Colebrants ◽  
Lore Thijs ◽  
Guichuan Li ◽  
...  
Keyword(s):  
Mechanical Performance ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Part Quality

scholarly journals Scale, Material Concentration, Stress Relief and Part Removal Effects on the Dimensional Behaviour of Selected AlSi10Mg Components Manufactured by Laser Powder Bed Fusion

2019 ◽  
Vol 3 (2) ◽  
pp. 49
Author(s):  
Floriane Zongo ◽  
Antoine Tahan ◽  
Vladimir Brailovski
Keyword(s):  
Shot Peening ◽  
Scale Effects ◽  
Three Dimensional ◽  
Stress Relief ◽  
Computer Assisted ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Before And After ◽  
3D Profile

Laser Powder Bed Fusion (LPBF) is a predominant Additive Manufacturing (AM) process. While metallic LPBF is gaining popularity, one of the barriers facing its wider industrial use is the current relatively limited knowledge with respect to its dimensional and geometrical performance, as well as the inability to predict it. This paper presents an experimental investigation of the geometrical and dimensional deviations of selected LPBF-manufactured components according to the ASME Y14.5 (2009) standard. In this study, two types of axisymmetric parts (cylinder and cylindrical pyramid) were designed with three different levels of material concentration, and replicated at three different scales for a total of 18 test artifacts. These parts were manufactured from AlSi10Mg powder using an EOSINT M280 printer, subjected to stress relief annealing at 300 °C for two hours, removed from the platform and finished by micro shot peening. A complete statistical analysis was carried out on the artifacts before and after each post-processing step. The results of this investigation allowed for the quantification of the intra- (same part) and inter- (different parts) scale effects, as well as of the material concentration, stress relief, part removal and micro shot peening effects on the overall three-dimensional (3D) profile deviations and on the dimensional deviations of some selected features (e.g., diameter, thickness). For example, cylindrical pyramid parts showed the following average deviations of their outside diameters: a −63 µm shrinkage of the as-built part diameter as compared to its computer-assisted design (CAD) value, a +20 µm expansion after stress relief annealing as compared to the precedent step, a −18 µm shrinkage after part removal and, finally, a −50 µm shrinkage after micro shot peening.

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