scholarly journals Rapid Alloy Development of Extremely High-Alloyed Metals Using Powder Blends in Laser Powder Bed Fusion

Materials ◽  
2019 ◽  
Vol 12 (10) ◽  
pp. 1706 ◽  
Author(s):  
Simon Ewald ◽  
Fabian Kies ◽  
Steffen Hermsen ◽  
Maximilian Voshage ◽  
Christian Haase ◽  
...  
Keyword(s):  
Microstructural Characterization ◽  
Chemical Compositions ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Alloy Development ◽  
Large Space ◽  
Powder Bed ◽  
High Entropy ◽  
Powder Blends ◽  
Rapid Alloy Development

The design of new alloys by and for metal additive manufacturing (AM) is an emerging field of research. Currently, pre-alloyed powders are used in metal AM, which are expensive and inflexible in terms of varying chemical composition. The present study describes the adaption of rapid alloy development in laser powder bed fusion (LPBF) by using elemental powder blends. This enables an agile and resource-efficient approach to designing and screening new alloys through fast generation of alloys with varying chemical compositions. This method was evaluated on the new and chemically complex materials group of multi-principal element alloys (MPEAs), also known as high-entropy alloys (HEAs). MPEAs constitute ideal candidates for the introduced methodology due to the large space for possible alloys. First, process parameters for LPBF with powder blends containing at least five different elemental powders were developed. Secondly, the influence of processing parameters and the resulting energy density input on the homogeneity of the manufactured parts were investigated. Microstructural characterization was carried out by optical microscopy, electron backscatter diffraction (EBSD), and energy-dispersive X-ray spectroscopy (EDS), while mechanical properties were evaluated using tensile testing. Finally, the applicability of powder blends in LPBF was demonstrated through the manufacture of geometrically complex lattice structures with energy absorption functionality.

scholarly journals Comparison of the Processability and Influence on the Microstructure of Different Starting Powder Blends for Laser Powder Bed Fusion of a Fe3.5Si1.5C Alloy

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1107
Author(s):  
Anna Luise Strauch ◽  
Volker Uhlenwinkel ◽  
Matthias Steinbacher ◽  
Felix Großwendt ◽  
Arne Röttger ◽  
...  
Keyword(s):  
Base Material ◽  
Model Alloy ◽  
Dissolution Behavior ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Alloy Development ◽  
Chemical Homogeneity ◽  
Powder Bed ◽  
Fe Powder ◽  
Powder Blends

This paper examines different blends of starting materials for alloy development in the laser powder bed fusion (LPBF) process. By using blends of individual elemental, ferroalloy and carbide powders instead of a pre-alloyed gas-atomized starting powder, elaborate gas-atomization processes for the production of individual starting powders with varying alloy compositions can be omitted. In this work the model alloy Fe3.5Si1.5C is produced by LPBF from different blends of pure elemental, binary and ternary powders. Three powder blends were processed. The base material for all powder blends is a commercial gas-atomized Fe powder. In the first blend this Fe powder is admixed with SiC, in the second with the ternary raw alloy FeSiC and in the third with FeSi and FeC. After characterizing the powder properties and performing LPBF parameter studies for each powder blend, the microstructures and the mechanical properties of the LPBF-manufactured samples were analyzed. Therefore, investigations were carried out by scanning electron microscopy, wave length dispersive x-ray spectroscopy and micro hardness testing. It was shown that the admixed SiC dissolves completely during LPBF. But the obtained microstructure consisting of bainite, martensite, ferrite and retained austenite is inhomogeneous. The use of the lower melting ferroalloys FeSi and FeC as well as the ternary ferroalloy FeSiC leads to an increased chemical homogeneity after LPBF-processing. However, the particle size of the used components plays a decisive role for the dissolution behavior in LPBF.

Compositionally graded AlxCoCrFeNi high-entropy alloy manufactured by laser powder bed fusion

Materialia ◽  
2021 ◽  
pp. 101308
Author(s):  
Fengxia Wei ◽  
Siyuan Wei ◽  
Kwang Boon Lau ◽  
Wei Hock Teh ◽  
Jing Jun Lee ◽  
...  
Keyword(s):  
High Entropy Alloy ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
High Entropy

High strength Al alloy development for laser powder bed fusion

2021 ◽  
pp. 2141001
Author(s):  
Jin’e Sun ◽  
Baicheng Zhang ◽  
Xuanhui Qu
Keyword(s):  
High Strength ◽  
Nucleation Site ◽  
Al Alloys ◽  
Hot Tearing ◽  
Al Alloy ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Alloy Development ◽  
Powder Bed ◽  
Columnar Grain

High strength Al alloy development is the key technique to additive manufacturing (AM) applied on lightweight of aerospace, automotive and military industry. Unlike the conventional wrought Al–Si eutectic alloys available for AM process, the strength of new developed Al alloy can be improved by in situ or additional nano-precipitated phase. This paper presents an overview of high strength Al alloys development including metallic additives, such as Zr, Sc, Mn, Cu, etc., and nanoparticle additives, such as ceramics (TiB2, TiC, LaB6 and TiN) as well as carbon nanotubes (CNTs). The addition of Zr and Sc elements significantly prevents hot tearing and enhances the strength of laser processed Al alloys because the nanoscale Al3Zr, Al3Sc and Al3 (Sc, Zr) precipitated phases generate, facilitate the heterogeneous nucleation of Al matrix and refine the microstructure. Moreover, the addition of Mn and Cu elements provides an increment in the toughness and strength of laser processed Al alloys through the superimposed effect of multi-element solid solution reinforcement and precipitation strengthening role of some Al2CuMg and Al6Mn. The growth process of Al alloy can be interrupted by the addition of nanoceramics particles as additional nucleation site which leads the columnar grain transforms to the equiaxed grain. Furthermore, the mechanism of mutual solubility of LaB6, TiB2, TiC and TiN in Al alloys is systematically studied. Finally, an assessment of the state in laser processed high strength Al alloys and the research demands for the expansion of laser powder bed fusion of Al metallic components are provided.

scholarly journals Printability and microstructure of the CoCrFeMnNi high-entropy alloy fabricated by laser powder bed fusion

2018 ◽  
Vol 224 ◽  
pp. 22-25 ◽  
Author(s):  
A. Piglione ◽  
B. Dovgyy ◽  
C. Liu ◽  
C.M. Gourlay ◽  
P.A. Hooper ◽  
...  
Keyword(s):  
High Entropy Alloy ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
High Entropy

scholarly journals Laser Powder Bed Fusion of Potential Superalloys: A Review

Metals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 58
Author(s):  
Prince Valentine Cobbinah ◽  
Rivel Armil Nzeukou ◽  
Omoyemi Temitope Onawale ◽  
Wallace Rwisayi Matizamhuka
Keyword(s):  
Computer Aided Design ◽  
Value Added ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
High Entropy ◽  
Controlled Processing ◽  
Structural Applications ◽  
Aided Design ◽  
Sintering Processes

The laser powder bed fusion (LPBF) is an additive manufacturing technology involving a gradual build-on of layers to form a complete component according to a computer-aided design. The LPBF process boasts of manufacturing value-added parts with higher accuracy and complex geometries for the transport, aviation, energy, and biomedical industries. TiAl-based alloys and high-entropy alloys (HEAs) are two materials envisaged as potential replacements of nickel-based superalloys for high temperature structural applications. The success of these materials hinge on optimization and implementation of tailored microstructures through controlled processing and appropriate alloy manipulations that can promote and stabilize new microstructures. Therefore, it is important to understand the LPBF technique, and its associated microstructure-mechanical property relationships. This paper discusses the metallurgical sintering processes of LPBF, the effects of process parameters on densification, microstructures, and mechanical properties of LPBFed TiAl-based alloys and HEAs. This paper also, presents updates and future studies recommendations on the LPBFed TiAl-based alloys and HEAs.

Bimetal printing of high entropy alloy/metallic glass by laser powder bed fusion additive manufacturing

2022 ◽  
Vol 141 ◽  
pp. 107430
Author(s):  
Hao Wang ◽  
Junquan Chen ◽  
Hailu Luo ◽  
Di Wang ◽  
Changhui Song ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Metallic Glass ◽  
High Entropy Alloy ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
High Entropy
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