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Title: SINTER B0NDING TITANIUM POWDER COMPONENTS: AN UNCONVENTIONAL ADDITIVE MANUFACTURING APPROACH
Creator: Montonera, Darrell R
Date: 2018, 2018-05
Description: Titanium and its alloys are desirable for many applications. The cost of producing titanium parts that also have needed microstructure for a...
Show moreTitanium and its alloys are desirable for many applications. The cost of producing titanium parts that also have needed microstructure for a given application limit where titanium is used. Methods of reducing the cost of titanium parts have been to use powder metallurgy processing routes. However, not all powder processing routes are cost effective, as additive manufacturing and powder injection molding processes are costly and require expensive spherical powder. Cheaper processing Press and Sinter utilizes cheaper non-spherical powder. Powder titanium components made through Press and Sinter have complexity, size, and geometrical constraints and have detrimental mechanical properties unless further post processing is done. To utilize the simple geometries from Press and Sinter, pressed powder components are bonded to examine the possibility of creating higher complexity parts. To achieve this, the dimensional sintering behavior of powders were quanti- ed using dilatometry. Grade 5 titanium alloys were created by blending hydridedehydride (HDH) commercially pure powder with master alloy (MA) 60/40 wt%. The dimensional effect of varying master alloy produced a maximum difference of 0.341% between an alloy with lower MA content compared to higher content during sintering. The sintering behavior of powder HDH+MA reached a nal shrinkage of 4.59%. Other powders TiH2, TiH2+MA, and Armstrong pre-alloyed had fi nal shrinkages of 9.85, 9.64, and 8.31%. The larger shrinkage powders were pressed into a peripheral component to be bonded to a HDH+MA core. Samples were sintered under a vacuum of 2x10􀀀6 torr by heating from room temperature to 1370 oC at 15 oCmin􀀀1 and holding at 1370 oC for 90 minutes. Sinter Bonded sample interfaces were examined showing the best bond to be the Armstrong j HDH+MA combination. This bond was tested using a push out test achieving shear stresses of 423 60 MPa using a pre-sintering tolerance between components of 0.065 mm and 444 37 MPa using a pre-sintering tolerance of 0.03 mm. Wrought material tested in the same manner as the sinter bonded components had a strength of 517 8 MPa. Sinter bonded samples achieved on average 82% the strength of wrought tested in the same manner. Strong bond strengths lead to a fatigue analysis of sinter bonded samples. Under various applied cyclic compressive stresses the number of cycles to failure were measured using an applied stress ratio R = 0.1. Determination of fatigue properties was done by simulating and probing in Abaqus the max tension stresses located at the bottom center of the sample. Simulations produced steady state tension stresses measured at maximum, mean, and minimum applied compressive stresses. These stresses were used to plot a S-N curve. True stress amplitudes were calculated from probed maximum and minimum stresses and the fatigue data were fi t to the Basquin empirical relation 2 = 810:4(2Nf )􀀀0:055 for sinter bonded samples and 2 = 1290:9(2Nf )􀀀0:065 for wrought samples. As a proof of concept several pressed titanium parts were combined in the green state and successfully sintered into a single component.
Ph.D. in Materials Science and Engineering, May 2018
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Title: ELECTROCHEMICAL BEHAVIOR OF ADDITIVELY MANUFACTURED NON-SPHERICAL TI-6AL-4V POWDER IN 3.5 WT. % NACL SOLUTION
Creator: Bagi, Sourabh Dilip
Date: 2021
Description: In laser powder bed fusion (LPBF), also known as selective laser melting (SLM), the feedstock powder and processing parameters affect the...
Show moreIn laser powder bed fusion (LPBF), also known as selective laser melting (SLM), the feedstock powder and processing parameters affect the properties of additively manufactured parts. Limited research has been conducted on non-spherical Ti6Al4V feedstock powder prepared by Hydride-Dehydride process. Significant progress in metal powder additive manufacturing (AM) requires the inter-linking of multiple variables, which includes starting materials, process settings, and post-treatment to achieve desired resultant properties. Owing to the rapid emergence of metal 3D-printing, process-property relationships, and appropriate post-treatment conditions have not been as extensively characterized as for conventional materials, thus requiring significant attention. Over the years, spherical powders were used in powder bed AM machines and there have been various concerns related to powder as well as processing parameters leading to defects formation, poor part quality, and unsatisfactory performance. It is critical to keep the cost of manufacturing low for large-scale production which results in significant interest in low-cost powder, making it vital to understand the effect of microstructural defects on corrosion behavior. Recently, economical powder attracted attention in AM, thus, making it is necessary to understand the role of possible microstructural defects on corrosion behavior. In powder bed additive manufacturing, feedstock and processing affect final microstructure and properties of the 3D printed parts. While numerous studies have evaluated 3D-printing of spherical powder, very limited research has examined the processing of the non-spherical feedstock. In this research, parts are manufactured by SLM of hydride-dehydride (HDH) Ti6Al4V powder. heat treatment and hot isostatic pressing are applied on SLM parts. The microstructures, potentiodynamic curves, and electrochemical impedance spectroscopy are characterized for SLM processed, heat treated, and hot isostatically pressed HDH Ti6Al4V specimens. Results indicate although the as-built specimen has anisotropic microstructure (i.e., lamellar α + acicular α’ + β phases), the heat treatment and hot isostatic pressing result in homogenized grain structures and enhanced corrosion behavior. Results indicate that type of constituent phase, grain size, and morphology directly determine corrosion resistance. This research is beneficial for the manufacturing of low-cost titanium alloys. In the current research, we evaluate non-spherical powder processing by hydride-dehydride (HDH) method and selective laser melted in powder bed AM machine followed by heat treatment and hot isostatic pressing to alter microstructure and electrochemical behavior. If successful, the usage of non-spherical morphology in conjunction with the newer powder dispensing method of double smoothing will enable remarkable improvements in the quality and performance of additively manufactured products. This method will also cut down costs associated with a greener powder production method and enhance the fabrication rate. It is a well-established fact that corrosion behavior is drastically affected by heterogeneous microstructure and defects. Thus, it is paramount to conduct a systematic study on the role of processing parameters and post process heat treatment, which can enhance our understanding of possible defect formation in micro and macro scale and their impact on electrochemical behavior.
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Title: Towards Understanding the Microstructure and Mechanical Properties of Additively Manufactured Ni-base Superalloys
Creator: Tiparti, Dhruv Reddy
Date: 2022
Description: Nickel-base superalloy components such as turbine discs typically undergo numerous manufacturing steps that contribute to increasing the cost...
Show moreNickel-base superalloy components such as turbine discs typically undergo numerous manufacturing steps that contribute to increasing the cost and the waste of excess materials. With advent of fusion based additive of manufacturing (AM) techniques, such components with complex geometry can be fabricated with great efficiency. However due to characteristically high energy densities, fast cooling rate, and layer-by-layer building process associated with AM; Ni-base superalloys with higher temperature performance are difficult to be fabricated by AM due to susceptibility to composition related defect formation, which is further exacerbated by anisotropic grain structures induced by the large thermal gradients present. Crack-free material can be fabricated but, in most cases, issues such as an anisotropic microstructure will prevail, and the balance of mechanical properties achieved may not be suitable for the desired applications. Several strategies exist to mitigate the challenges posed by additive manufacturing via post-processing such as hot-isostatic processing, annealing heat treatments, application of grain refining inoculants, etc. All these strategies utilized to mitigate issues with AM of Ni-base superalloys still require further study to understand their effects on the microstructure and mechanical properties. This work aims to evaluate the use of inoculant particles, and novel heat treatments on the microstructure and mechanical properties of different superalloys. First, the effect of varying amounts of CoAl2O4 inoculant ranging from 0 to 2 wt.% on the microstructure evolution of Inconel 718(IN718) fabricated by selective laser melting (SLM) was evaluated. The findings from this study indicated that additions of CoAl2O4 only resulted in a minor degree of grain refinement with slight increase in anisotropy; in addition, a CoAl2O4 ¬content above 0.2 wt.% resulted in the formation of agglomerate inclusions; and that to effectively utilize CoAl2O4 as a grain refining inoculant, process parameters must be further optimized while considering the formation of agglomerates, and other defects. Second, the application of CoAl2¬O4 was extended towards the Direct Energy Deposition (DED) of IN718. Here findings indicated that due to the modification of the thermophysical properties of the melt pool by oxide addition, an earlier onset of large columnar extending across multiple layers occurred while counteracting conditions required for equiaxed grain formation; and these CoAl2O4 were also found to exhibit a potent Zenner pinning effect that maintained the as-built grain structure despite application of extreme high treatment condition of 1200oC for 4 hrs. Third, the tensile and fatigue properties of the DED IN718 with CoAl2O4 were evaluated. Here, it was found that the addition of CoAl2O4 leads to a minor increase in tensile strength in the as-built condition attributed primarily to the fine oxide dispersion; a more modest increase in tensile strength in the heat-treated condition due to grain refinement induced by retaining the as-built grain structure; and that despite the increase in tensile strength with CoAl2O4 a corresponding increase in fatigue life did not occur. Lastly, the processing of René 65 conducted by laser-powder bed fusion(L-PBF) was done and compared to the conventionally cast and wrought material. Here, the effect of the difference in processing route in conjunction with heat treatments was evaluated to understand the creep and stress relaxation behavior. It was found that L-PBF of René 65 led to an overall improved resistance to deformation by creep and relaxation mechanism.
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Title: Laser Powder Bed Fusion Of Cost-Effective Non-Spherical Ti-6Al-4V Powder
Creator: Asherloo, Mohammadreza
Date: 2023
Description: This comprehensive research delves into the intricate dynamics of Laser Powder Bed Fusion (L-PBF) of Ti-6Al-4V powders, emphasizing the...
Show moreThis comprehensive research delves into the intricate dynamics of Laser Powder Bed Fusion (L-PBF) of Ti-6Al-4V powders, emphasizing the potential of non-spherical, hydride-dehydride (HDH) powders as a cost-efficient alternative to traditional spherical powders. The study systematically explores the interplay between powder morphology, granulometry, and various post-processing treatments in shaping the resultant microstructure, porosity, and mechanical properties of L-PBF fabricated Ti-6Al-4V components.Initial investigations focused on the flowability, packing density, and resultant density of L-PBF parts using HDH powders with varying size distributions. Through meticulous optimization of laser parameters, parts with a relative density exceeding 99.5% were achieved, even at production rates 1.5–2 times higher than conventional LPBF processes. Dynamic synchrotron X-ray imaging provided insights into laser-powder interactions, revealing key mechanisms of porosity formation associated with HDH powders. Further microstructural examinations highlighted the formation of columnar β grains with acicular α/α′ phases in the as-built condition. Mechanical tests, including fatigue assessments under fully-reversed tension-compression conditions, revealed the critical role of surface roughness in fatigue performance. Notably, mechanical grinding significantly improved fatigue strength, especially in the high cycle fatigue region, by eliminating surface micro-notches. X-ray diffraction analyses further elucidated the stress and micro-strain profiles, offering insights into the material's deformation mechanisms. A pivotal discovery was the presence of α/α′ on prior β/β grain boundaries, challenging the prevailing notion that high cooling rates in L-PBF preclude β/β grain boundary variant selection. Electron backscatter diffraction and synchrotron X-ray imaging illuminated the role of powder characteristics in locally modulating cooling rates, leading to β/β grain boundary α′ lath growth. Lastly, the research underscored the multifaceted interdependencies among contouring, powder granulometry, Hot Isostatic Pressing (HIP), and mechanical surface treatments. A pronounced increase in sub-surface porosities was identified when contouring was combined with fine powder granulometry. However, post-HIP treatments induced a phase transformation from martensitic α′ to a basket-weave α+β microstructure, enhancing the material's fatigue resistance to levels comparable to wrought Ti-6Al-4V. In summation, this doctoral research offers a holistic understanding of the L-PBF process for Ti-6Al-4V, emphasizing the viability of non-spherical HDH powders and providing a roadmap for parameter optimization, defect minimization, and mechanical property enhancement in L-PBF-fabricated Ti-6Al-4V structures.
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