Laser additive manufacturing of copper– chromium–niobium alloys using gas atomized powder

2020 ◽  
Vol 111 (7) ◽  
pp. 587-593
Author(s):  
Dora Maischner ◽  
Udo Fritsching ◽  
Anoop Kini ◽  
Andreas Weisheit ◽  
Volker Uhlenwinkel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Elevated Temperatures ◽  
High Strength ◽  
Copper Matrix ◽  
Metal Deposition ◽  
Raw Material ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
Niobium Alloys

Abstract Copper-chrome-niobium alloys exhibit excellent thermal and electrical properties combined with high strength at elevated temperatures. Additive manufacturing techniques such as laser metal deposition using powder as raw material offer the potential for rapid solidification as well as a high freedom of design to manufacture parts layer by layer. Powder samples of copper- chrome-niobium alloys were produced by gas atomization. Via laser metal deposition, bulk volumes without cracks and with a very low porosity can be built up. Rapid solidification leads to the formation of fine precipitates which are likely to be (Cr,Fe)2Nb. The precipitates are distributed homogeneously in the copper matrix. The copper crystals grow across the layers due to epitaxial nucleation on the preceding layer.

Additive Manufacturing

2019 ◽  
pp. 165-183 ◽  
Author(s):  
Kamardeen Olajide Abdulrahman ◽  
Esther T. Akinlabi ◽  
Rasheedat M. Mahamood
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Titanium Aluminide ◽  
Three Dimensional ◽  
Physical And Mechanical Properties ◽  
Processing Parameters ◽  
Metal Deposition ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
Additive Process

Three-dimensional printing has evolved into an advanced laser additive manufacturing (AM) process with capacity of directly producing parts through CAD model. AM technology parts are fabricated through layer by layer build-up additive process. AM technology cuts down material wastage, reduces buy-to-fly ratio, fabricates complex parts, and repairs damaged old functional components. Titanium aluminide alloys fall under the group of intermetallic compounds known for high temperature applications and display of superior physical and mechanical properties, which made them most sort after in the aeronautic, energy, and automobile industries. Laser metal deposition is an AM process used in the repair and fabrication of solid components but sometimes associated with thermal induced stresses which sometimes led to cracks in deposited parts. This chapter looks at some AM processes with more emphasis on laser metal deposition technique, effect of LMD processing parameters, and preheating of substrate on the physical, microstructural, and mechanical properties of components produced through AM process.

scholarly journals Additive Manufacturing of H11 with Wire-Based Laser Metal Deposition

2017 ◽  
Vol 22 (4) ◽  
pp. 466-479 ◽  
Author(s):  
Stella Holzbach Oliari ◽  
Ana Sofia Clímaco Monteiro D’Oliveira ◽  
Martin Schulz
Keyword(s):  
Additive Manufacturing ◽  
Travel Speed ◽  
Metal Deposition ◽  
Parameters Optimization ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
3D Cad ◽  
Deposition Parameters ◽  
Commercial Applications ◽  
Functional Components

Abstract Laser additive manufacturing (LAM) is a near-net-shape production technique by which a part can be built up from 3D CAD model data, without material removal. Recently, these production processes gained attention due to the spreading of polymer-based processes in private and commercial applications. However, due to the insufficient development of metal producing processes regarding design, process information and qualification, resistance on producing functional components with this technology is still present. To overcome this restriction further studies have to be undertaken. The present research proposes a parametric study of additive manufacturing of hot work tool steel, H11. The selected LAM process is wire-based laser metal deposition (LMD-W). The study consists of parameters optimization for single beads (laser power, travel speed and wire feed rate) as well as lateral and vertical overlap for layer-by-layer technique involved in LMD process. Results show that selection of an ideal set of parameters affects substantially the surface quality, bead uniformity and bond between substrate and clad. Discussion includes the role of overlapping on the soundness of parts based on the height homogeneity of each layer, porosity and the presence of gaps. For the conditions tested it was shown that once the deposition parameters are selected, lateral and vertical overlapping determines the integrity and quality of parts processed by LAM.

scholarly journals Build-up strategies for additive manufacturing of three dimensional Ti-6Al-4V-parts produced by laser metal deposition

2018 ◽  
Vol 30 (2) ◽  
pp. 022001 ◽  
Author(s):  
Felix Spranger ◽  
Benjamin Graf ◽  
Michael Schuch ◽  
Kai Hilgenberg ◽  
Michael Rethmeier
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Metal Deposition ◽  
Laser Metal Deposition

Additive Manufacturing of Nickel-Based Super Alloys for Aero Engine Applications

2020 ◽  
pp. 48-70
Author(s):  
Raja A. ◽  
Mythreyi O. V. ◽  
Jayaganthan R.
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Source Parameters ◽  
Raw Material ◽  
Layer By Layer ◽  
Powder Bed ◽  
Complex Design ◽  
Direct Energy ◽  
Second Phases ◽  
Metal Addition

Ni based super alloys are widely used in engine turbines because of their proven performance at high temperatures. Manufacturing these parts by additive manufacturing (AM) methods provides researchers a lot of creative space for complex design to improve efficiency. Powder bed fusion (PBF) and direct energy deposition (DED) are the two most widely-used metal AM methods. Both methods are influenced by the source, parameters, design, and raw material. Selective laser melting is one of the laser-based PBF techniques to create small layer thickness and complex geometry with greater accuracy and properties. The layer-by-layer metal addition generates epitaxial growth and solidification in the built direction. There are different second phases in the Ni-based superalloys. This chapter details the micro-segregation of these particles and its influence on the microstructure, and mechanical properties are dependent on the process influencing parameters, the thermal kinetics during the process, and the post-processing treatments.

scholarly journals Simplified numerical model for the laser metal deposition additive manufacturing process

2017 ◽  
Vol 29 (2) ◽  
pp. 022304 ◽  
Author(s):  
Patrice Peyre ◽  
Morgan Dal ◽  
Sébastien Pouzet ◽  
Olivier Castelnau
Keyword(s):  
Additive Manufacturing ◽  
Numerical Model ◽  
Manufacturing Process ◽  
Metal Deposition ◽  
Laser Metal Deposition

scholarly journals Repetitive Process Control of Additive Manufacturing With Application to Laser Metal Deposition

2019 ◽  
Vol 27 (2) ◽  
pp. 566-575 ◽  
Author(s):  
Patrick M. Sammons ◽  
Michelle L. Gegel ◽  
Douglas A. Bristow ◽  
Robert G. Landers
Keyword(s):  
Additive Manufacturing ◽  
Process Control ◽  
Metal Deposition ◽  
Laser Metal Deposition ◽  
Repetitive Process

Height Dependent Laser Metal Deposition Process Modeling

2013 ◽  
Vol 135 (5) ◽  
Author(s):  
Patrick M. Sammons ◽  
Douglas A. Bristow ◽  
Robert G. Landers
Keyword(s):  
Heat Transfer ◽  
Critical Role ◽  
Metal Deposition ◽  
Lumped Parameter Model ◽  
Analytical Models ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
Melt Pool ◽  
Solid Region ◽  
Scan Speed

Laser metal deposition (LMD) is used to construct functional parts in a layer-by-layer fashion. The heat transfer from the melt region to the solid region plays a critical role in the resulting material properties and part geometry. The heat transfer dynamics can change significantly as the number of layers increase, depending on the geometry of the sub layers. However, this effect is not taken into account in previous analytical models, which are only valid for a single layer. This paper develops a layer dependent model of the LMD process for the purpose of designing advanced layer-to-layer controllers. A lumped-parameter model of the melt pool is introduced and then extended to include elements that capture height dependent effects on the melt pool dimensions and temperature. The model dynamically relates the process inputs (laser power, material mass flow rate, and scan speed) to the melt pool dimensions and temperature. A finite element analysis (FEA) is then conducted to determine the effect of scan speed and part height on the solid region temperature gradient at the melt pool solidification boundary. Finally, experimental results demonstrate that the model successfully predicts multilayer phenomenon for two deposits on two different substrates.

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