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Material transitions within multi-material laser deposited intermetallic Iron Aluminides
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Product and Production Development. Siemens AG, Otto-Hahn-Ring 6, 81739 München, Germany.ORCID iD: 0000-0002-3403-5602
Siemens AG, München, Germany.
Siemens AG, München, Germany.
Siemens AG, Berlin, Germany.
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2020 (English)In: Additive Manufacturing, ISSN 2214-8604, E-ISSN 2214-7810, Vol. 34, article id 101242Article in journal (Refereed) Published
Abstract [en]

Laser Metal Deposition is a near-net-shape processing technology, which allows remarkable freedom in multi-material processing. In the present work, the multi-material processing of two intermetallic iron aluminides, Fe28Al(at.%) and Fe30Al5Ti0.7B(at.%), was investigated. It has been shown that multi-material processing of the two alloys via discrete as well as via gradual material transition is possible without any cracks for manufacturing small cubes. Cross-sections of manufactured parts and tracks showed that a preheating temperature of at least 400 °C is necessary to process crack free samples. EDX-analyses indicated that if a discrete material transition is required in multi-material processing, the material transition should be implemented in the vertical build-up direction because the mixing zone in this direction is significantly smaller than the mixing zone in the horizontal direction. Due to the stronger mixing effects in the horizontal direction, a gradual material transition by a linear progression should be implemented in this direction rather than in the vertical direction. The mixing effects are mainly caused by melt flow, while diffusion effects can be neglected.

Place, publisher, year, edition, pages
Elsevier, 2020. Vol. 34, article id 101242
Keywords [en]
Additive Manufacturing, Multi-material processing, Direct Energy Deposition, Laser Metal Deposition, Functionally Graded Material
National Category
Manufacturing, Surface and Joining Technology
Research subject
Manufacturing Systems Engineering
Identifiers
URN: urn:nbn:se:ltu:diva-78716DOI: 10.1016/j.addma.2020.101242ISI: 000555843600002Scopus ID: 2-s2.0-85084494684OAI: oai:DiVA.org:ltu-78716DiVA, id: diva2:1427206
Note

Validerad;2020;Nivå 2;2020-09-01 (johcin)

Available from: 2020-04-29 Created: 2020-04-29 Last updated: 2021-12-13Bibliographically approved
In thesis
1. In-situ analysis of process characteristics in Directed Energy Deposition
Open this publication in new window or tab >>In-situ analysis of process characteristics in Directed Energy Deposition
2022 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

In recent years, the interest in Additive Manufacturing on an industrial scale has risen due to the various new processes and the increase in potential use cases. In this thesis, the two Additive Manufacturing processes, Wire Arc Additive Manufacturing and Laser Metal Deposition were investigated. Both processes belong to the Directed Energy Deposition processes in Additive Manufacturing and are already used in different industrial areas such as automotive, aviation, railway, or medical engineering. A major challenge for the industrialization of Additive Manufacturing is the insufficient quality and repeatability of the manufactured parts due to the complexity of the processes and the lack of process knowledge. Therefore, this work focused on a deeper understanding of the process characteristics and their correlations with different sensors used for in-situ analysis.  One of the sensors used for in-situ analysis was high-speed imaging. High-speed imaging during Wire Arc Additive Manufacturing revealed that different lead angles of the welding torch have an influence on fluctuation effects in the manufactured structures. To avoid such fluctuation effects, which mainly origin from too low or too high interlayer temperatures, it was found that a pushing Wire Arc Additive Manufacturing process with a slightly tilted lead angle is working best. Apart from fluctuation effects, oxidation of aluminium can be also critical for the process stability of Wire Arc Additive Manufacturing. It was found that the surface oxidation on aluminium parts changed from an amorphous oxide layer into a white duplex oxide layer during the process. It was also found that oxidation anomalies, which can occur during processing due to process instabilities or lack of shielding gas, can be detected by light emission spectroscopy during manufacturing as peaks in the light spectrum arise when they occur. Another challenge in Wire Arc Additive Manufacturing of aluminium is the porosity in parts as it can have a significant impact on the resulting mechanical properties. It has been observed that as the shielding gas flow rate increases, the porosity in aluminium parts also increases due to the rapid solidification of the melt pool by the forced convection of gas flow. In addition, it has been shown that gas inclusions escaping from the melt pool leave cavities on the surface that can be observed by process imaging, which reveals information about the porosity of the part. Another promising sensor for in-situ analysis of the process characteristics are microphones that capture acoustic emissions. For Wire Arc Additive Manufacturing, the investigations showed that the main acoustic emissions origin from the plasma expansion of the arc. The acoustic emissions and the process anomalies that occur correlate mainly with the size of the arc because that is essentially the ionized volume that leads to the air pressure and causes the acoustic emissions. For Laser Metal Deposition, it was found that the main acoustic emissions are created by the interaction between the powder particles and the laser beam, because they create an air pressure when the particles expand from the solid state to the liquid state while melting. Another major area investigated in this thesis was multi-material Additive Manufacturing, as process and material characteristics can change significantly. For processing of multi-material parts in Wire Arc Additive Manufacturing, it was found that the strength was limited by the properties of the individual aluminium alloys and not by those of the material transition zones. Process monitoring algorithms have been investigated to determine the chemical composition of the processed material. It was shown that the voltage, current, acoustic, and spectral emission data can be used for in-situ analysis of the chemical differences between two aluminium alloys. For Laser Metal Deposition, the design freedom of Additive Manufacturing with multiple materials was also demonstrated. It was shown that material transitions can be implemented discrete and graded, but the gradual material transition showed advantages in avoiding cracks in the material transition zones. In summary, all scientific papers contributed to a deeper process understanding of the process, the processed materials, and the resulting mechanical properties. In addition, the contributions provided crucial insights into the interrelationships of the process characteristics and the physical principles of various sensors used for in-situ analysis of the processes. 

Place, publisher, year, edition, pages
Luleå University of Technology, 2022
Series
Doctoral thesis / Luleå University of Technology 1 jan 1997 → …, ISSN 1402-1544
National Category
Manufacturing, Surface and Joining Technology
Research subject
Manufacturing Systems Engineering
Identifiers
urn:nbn:se:ltu:diva-88287 (URN)978-91-7790-997-2 (ISBN)978-91-7790-998-9 (ISBN)
Public defence
2022-03-03, A1545, Luleå, 09:00 (English)
Opponent
Supervisors
Available from: 2021-12-14 Created: 2021-12-13 Last updated: 2022-02-14Bibliographically approved

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Hauser, TobiasVolpp, JoergKaplan, Alexander F.H.

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