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ELECTROCHEMICAL BEHAVIOR OF ADDITIVELY MANUFACTURED NON-SPHERICAL TI-6AL-4V POWDER IN 3.5 WT. % NACL SOLUTION
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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Laser Powder Bed Fusion Of Cost-Effective Non-Spherical Ti-6Al-4V Powder
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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