TY - CONF A1 - Ávila Calderón, Luis Alexander A1 - Rehmer, Birgit A1 - Graf, B. A1 - Ulbricht, Alexander A1 - Skrotzki, Birgit A1 - Rethmeier, Michael T1 - Low cycle fatigue behavior of DED-L Ti-6AL-4V N2 - Laser powder-based directed energy deposition (DED-L) is a technology that offers the possibility for 3D material deposition over hundreds of layers and has thus the potential for application in additive manufacturing (AM). However, to achieve broad industrial application as AM technology, more data and knowledge about the fabricated materials regarding the achieved properties and their relationship to the manufacturing process and the resulting microstructure is still needed. In this work, we present data regarding the low-cycle fatigue (LCF) behavior of Ti-6Al-4V. The material was fabricated using an optimized DED-L process. It features a low defect population and excellent tensile properties. To assess its LCF behavior two conventionally manufactured variants of the same alloy featuring different microstructures were additionally tested. The strain-controlled LCF tests were carried out in fully reversed mode with 0.3 % to 1.0 % axial strain amplitude from room temperature up to 400°C. The LCF behavior and failure mechanisms are described. For characterization, optical microscopy (OM), scanning electron microscopy (SEM), and micro-computed tomography (µCT) were used. The low defect population allows for a better understanding of the intrinsic material’s properties and enables a fairer comparison against the conventional variants. The fatigue lifetimes of the DED-L material are nearly independent of the test temperature. At elevated test temperatures, they are similar or higher than the lifetimes of the conventional counterparts. At room temperature, they are only surpassed by the lifetimes of one of them. The principal failure mechanism involves multiple crack initiation sites. T2 - Ninth International Conference on Low Cycle Fatigue (LCF9) CY - Berlin, Germany DA - 21.06.2022 KW - AGIL KW - Additive Manufacturing KW - Ti-6Al-4V KW - Low-Cycle-Fatigue KW - Microstructure PY - 2022 AN - OPUS4-55123 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Mishurova, Tatiana A1 - Evsevleev, Sergei A1 - Artzt, K. A1 - Haubrich, J. A1 - Sevostianov, I. A1 - Requena, G. A1 - Bruno, Giovanni T1 - Micromechanical behavior of annealed Ti-6Al-4V produced by Laser Powder Bed Fusion N2 - The micromechanical behavior of an annealed Ti-6Al-4V material produced by Laser Powder Bed Fusion was characterized by means of in-situ synchrotron X-ray diffraction during a tensile test. The lattice strain evolution was obtained parallel and transversal to the loading direction. The elastic constants were determined and compared with the conventionally manufactured alloy. In the plastic regime, a lower plastic anisotropy exhibited by the lattice planes was observed along the load axis (parallel to the building direction) than in the transverse direction. Also, the load transfer from α to β phase was observed, increasing global ductility of the material. The material seems to accumulate a significant amount of intergranular strain in the transverse direction. KW - Additive manufacturing KW - Ti-6Al-4V KW - Anisotropy KW - Intergranular strain KW - Synchrotron X-ray diffraction PY - 2022 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-547406 VL - 2 IS - 1 SP - 186 EP - 201 PB - Taylor & Francis AN - OPUS4-54740 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - THES A1 - Mishurova, Tatiana T1 - Influence of residual stress and microstructure on mechanical performance of LPBF TI-6AL-4V N2 - Additive manufacturing technologies provide unique possibilities in the production of topologically optimized, near-net shape components. The main limiting factors affecting the structural integrity of Laser Powder Bed Fusion (LPBF) parts are manufacturing defects and residual stress (RS) because both of them are virtually inevitable. Taking into account the complex thermal history of LPBF materials, a prediction of the material behavior is not possible without experimental data on the microstructure, defect distribution, and RS fields. Therefore, this thesis aims to understand the factors that influence the LPBF Ti-6Al-4V material performance the most, covering both the production and the post-processing steps of manufacturing. Indeed, a parametric study on the influence of manufacturing process and post-processing on RS, defects and microstructure was performed. It was found that the volumetric energy Density (EV), commonly used for the LPBF process optimization, does neither consider the pore shapes and distribution, nor the influence of individual parameters on the volume fraction of pores. Therefore, it was recommended not to use EV without great care. It was shown that the Position on the base plate has a great impact on the amount of RS in the part. The micromechanical behavior of LPBF Ti-6Al-4V was also studied using in-situ Synchrotron X-ray diffraction during tensile and compression tests. Diffraction elastic constants (DEC), connecting macroscopic stress and (micro) strain, of the LPBF Ti-6Al-4V showed a difference from the DEC of conventionally manufactured alloy. This fact was attributed to the peculiar microstructure and crystallographic texture. It was therefore recommended to determine experimentally DECs whenever possible. Low Cycle Fatigue (LCF) tests at a chosen operating temperature were performed to evaluate the effect of post-treatment on the mechanical performance. Through the information on the microstructure, the mesostructure, and the RS, the LCF behavior was (indirectly) correlated to the process parameters. It was found that the fatigue performance of LPBF samples subjected to hot isostatic pressing is similar to that of hot-formed Ti-6Al-4V. The tensile RS found at the surface of LPBF as-built samples decreased the fatigue life compared to the heat-treated samples. The modification of the microstructure (by heat treatment) did not affect the Fatigue performance in the elastic regime. This shows that in the absence of tensile RS, the manufacturing defects solely control the failure of LPBF components and densification has the strongest effect on the improvement of the mechanical performance. KW - Additive manufacturing KW - Ti-6Al-4V KW - Residual stress KW - Computed tomography PY - 2021 SP - 1 EP - 143 CY - RWTH Aachen AN - OPUS4-54389 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Ivanov, S. A1 - Artinov, Antoni A1 - Zemlyakov, E. A1 - Karpov, I. A1 - Rylov, S. A1 - Em, V. T1 - Spatiotemporal Evolution of Stress Field during Direct Laser Deposition of Multilayer Thin Wall of Ti-6Al-4V N2 - The present work seeks to extend the level of understanding of the stress field evolution during direct laser deposition (DLD) of a 3.2 mm thick multilayer wall of Ti-6Al-4V alloy by theoretical and experimental studies. The process conditions were close to the conditions used to produce large-sized structures by the DLD method, resulting in specimens having the same thermal history. A simulation procedure based on the implicit finite element method was developed for the theoretical study of the stress field evolution. The accuracy of the simulation was significantly improved by using experimentally obtained temperature-dependent mechanical properties of the DLD-processed Ti-6Al4V alloy. The residual stress field in the buildup was experimentally measured by neutron diffraction. The stress-free lattice parameter, which is decisive for the measured stresses, was determined using both a plane stress approach and a force-momentum balance. The influence of the inhomogeneity of the residual stress field on the accuracy of the experimental measurement and the validation of the simulation procedure are analyzed and discussed. Based on the numerical results it was found that the non-uniformity of the through-thickness stress distribution reaches a maximum in the central cross-section, while at the buildup ends the stresses are distributed almost uniformly. The components of the principal stresses are tensile at the buildup ends near the substrate. Furthermore, the calculated equivalent plastic strain reaches 5.9% near the buildup end, where the deposited layers are completed, while the plastic strain is practically equal to the experimentally measured ductility of the DLD-processed alloy, which is 6.2%. The experimentally measured residual stresses obtained by the force-momentum balance and the plane stress approach differ slightly from each other. KW - Direct laser deposition KW - Finite element simulation KW - Neutron diffraction KW - Residual stresses KW - Ti-6Al-4V KW - Mechanical properties PY - 2022 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-542444 VL - 15 IS - 263 SP - 1 EP - 20 PB - MDPI AN - OPUS4-54244 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Pauzon, C. A1 - Mishurova, Tatiana A1 - Evsevleev, Sergei A1 - Dubiez-Le Goff, S. A1 - Murugesan, S. A1 - Bruno, Giovanni A1 - Hryha, E. T1 - Residual stresses and porosity in Ti-6Al-4V produced by laser powder bed fusion as a function of process atmosphere and component design N2 - The influence of the process gas, laser scan speed, and sample thickness on the build-up of residual stresses and porosity in Ti-6Al-4V produced by laser powder bed fusion was studied. Pure argon and helium, as well as a mixture of those (30% helium), were employed to establish process atmospheres with a low residual Oxygen content of 100 ppm O2. The results highlight that the subsurface residual stresses measured by X-ray diffraction were significantly lower in the thin samples (220 MPa) than in the cuboid samples (645 MPa). This difference was attributed to the shorter laser vector length, resulting in heat accumulation and thus in-situ stress relief. The addition of helium to the process gas did not introduce additional subsurface residual stresses in the simple geometries, even for the increased scanning speed. Finally, larger deflection was found in the cantilever built under helium (after removal from the baseplate), than in those produced under argon and an argon-helium mixture. This result demonstrates that complex designs involving large scanned areas could be subjected to higher residual stress when manufactured under helium due to the gas’s high thermal conductivity, heat capacity, and thermal diffusivity. KW - Additive manufacturing KW - Ti-6Al-4V KW - Residual stress KW - Process atmosphere KW - Helium PY - 2021 U6 - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:kobv:b43-534209 VL - 47 SP - 2340 PB - Elsevier B.V. AN - OPUS4-53420 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Graf, B. A1 - Schuch, M. A1 - Petrat, T. A1 - Gumenyuk, Andrey A1 - Rethmeier, Michael T1 - Combined laser additive manufacturing with powderbed and powder nozzle for turbine parts N2 - Metal additive manufacturing is often based on laser beam processes like Laser Metal Fusion (LMF) or Laser Metal Deposition (LMD). The LMF process is in particular suitable for very complex geometries. However build rate, part volume and material flexibility are limited in LMF. In contrast, LMD achieves higher deposition rates, less restricted part sizes and the possibility to change the material composition during the build-up process. On the other hand, due to the lower spatial precision of the material deposition process, the complexity of geometries is limited. Therefore, combined manufacturing with both LMF and LMD has the potential to utilize the respective advantages of both technologies. In this paper, combined additive manufacturing with LMF and LMD is described for Ti-6Al-4V and Inconel 718. First, lattice structures with different wall thickness and void sizes are built with LMF. The influence of LMD material deposition on these LMF-structures is examined regarding metallurgical impact and distortion. Cross-sections, x-ray computer tomography and 3D-scanning results are shown. For the titanium alloy specimen, oxygen and Nitrogen content in the deposited material are analysed to evaluate the LMD shielding gas atmosphere. The results are used to develop guidelines for a LMD build-up strategy on LMF substrates. With these findings, a gas turbine burner is manufactured as reality test for the combined approach. T2 - 6th International Conference on Additive Technologies iCAT 2016 CY - Nürnberg, Germany DA - 29.11.2016 KW - Ti-6Al-4V KW - Inconel 718 KW - Combined laser manufacturing PY - 2016 SN - 978-691-285-537-6 SP - 317 EP - 323 AN - OPUS4-38702 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Petrat, T. A1 - Graf, B. A1 - Gumenyuk, Andrey A1 - Rethmeier, Michael ED - Witt, G. ED - Eichmann, M. ED - Kniffka, W. T1 - Strategien zur Erreichung eines konstanten Volumenaufbaus bei der additiven Fertigung mittels Laser-Pulver-Auftragschweißen T1 - Strategies to achieve constant build-up with laser metal deposition N2 - Der Einsatz von Hochleistungswerkstoffen verlangt nach einer hohen Endformnähe der zu fertigenden Bauteile, um den Aufwand und somit die Kosten für Materialeinsatz und Nachbearbeitung möglichst gering zu halten. Der additive Einsatz in Form des Laser-Pulver-Auftragschweißens bietet hierfür durch den gezielten Materialauftrag ein hohes Potential. Herausforderungen bestehen in Bereichen der Vorhersagbarkeit und der Reproduzierbarkeit des Materialauftrages, sowie der Fertigungszeit. Unterschiedliche Einflüsse bei der Schichterzeugung führen dabei zu Abweichungen von der Soll-Geometrie. Die vorliegenden Untersuchungen behandeln den Einfluss von Spurgeometrie, Spurüberlappung, Verfahrweg und Aufbaureihenfolge auf die entstehende Bauteilform. Die Teilung einer Lage in Rand- und Kernbereich ermöglicht einen konturangepassten Verfahrweg und eine Erhöhung der Endformnähe innerhalb einer Ebene. Die Verwendung unterschiedlicher Spurgrößen bei der Bauteilerzeugung verdeutlicht die Möglichkeiten einer hohen Auftragsrate bei gleichzeitig hoher Formgenauigkeit. Bereits kleine Unterschiede beim Materialauftrag zwischen Kern- und Randbereichen, Start- und Endpunkten sowie in Bereichen des Richtungswechsels führen aufgrund von Fehlerfortpflanzung nachmehreren Lagen zu Abweichungen in der Aufbaurichtung. Kompensierungen mittels angepasster Baustrategien werden aufgezeigt und diskutiert. Die Nickelbasislegierung Inconel 718, die Titanlegierung Ti-6Al-4V sowie der austenitische Stahl 316L sind Bestandteil der vorliegenden Untersuchungen. Die gewonnenen Erkenntnisse verdeutlichen das Potenzial einer angepassten Aufbaustrategie zur reproduzierbaren Erzeugung von Bauteilen am Beispiel unterschiedlicher Körpergeometrien. T2 - Rapid.Tech International Trade Show & Conference for Additive Manufacturing CY - Erfurt, Germany DA - 14.06.2016 KW - Laser-Pulver-Auftragschweißen KW - Additive Fertigung KW - Aufbaustrategie KW - 3DDruck KW - Ti-6Al-4V KW - Inconel 718 KW - 316L PY - 2016 SN - 978-3-446-45017-2 SP - 49 EP - 60 PB - Carl Hanser Verlag CY - München, Germany AN - OPUS4-36571 LA - deu AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Mishurova, Tatiana A1 - Cabeza, Sandra A1 - Artzt, Katia A1 - Bruno, Giovanni A1 - Haubrich, Jan A1 - Requena, Guillermo T1 - Subsurface Residual Stress Analysis in Ti-6Al-4V Additive Manufactured Parts by Synchrotron X-ray Diffraction N2 - Synchrotron X-ray diffraction is a powerful non-destructive technique for the analysis of the material stress-state. High cooling rates and heterogeneous temperature distributions during additive manufacturing lead to high residual stresses. These high residual stresses play a crucial role in the ability to achieve complex geometries with accuracy since they can promote distortion of parts during manufacturing. Furthermore, residual stresses are critical for the mechanical performance of parts in terms of durability and safety. In the present study, Ti-6Al-4V bridge-like specimens were manufactured additively by selective laser melting (SLM) under different laser scanning speed conditions in order to compare the effect of process energy density on the residual stress state. Subsurface residual stress analysis was conducted by means of synchrotron X-ray diffraction in energy dispersive mode for three conditions: as-built on base plate, released from base plate, and after heat treatment on the base plate. The quantitative residual stress characterization shows a correlation with the qualitative bridge curvature method. Computed tomography (CT) was carried out to ensure that no stress relief took place owing to the presence of porosity. CT allows obtaining spatial and size pores distribution which helps in optimization of the SLM process. High tensile residual stresses were found at the lateral surface for samples in the as-built conditions. We observed that higher laser energy density during fabrication leads to lower residual stresses. Samples in released condition showed redistribution of the stresses due to distortion. T2 - ECNDT 2018 CY - Göteborg, Sweden DA - 11.06.2018 KW - Additive manufacturing KW - Selective laser melting KW - Residual stress KW - Computed tomography KW - Ti-6Al-4V PY - 2018 AN - OPUS4-45202 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Graf, B. A1 - Marko, A. A1 - Petrat, T. A1 - Gumenyuk, Andrey A1 - Rethmeier, Michael T1 - 3D laser metal deposition in an additive manufacturing process chain N2 - Laser metal deposition is described with its applications for additive manufacturing. The necessary process chain is discussed, with regard to weld bead dimensions and 3D build-up strategy. Metallurgical cross sections, x-ray and tensile tests are conducted. As demonstrative components, a gas turbine burner and a turbine blade are shown T2 - 1st International Congress on Welding, Additive Manufacturing and Associated Non-Destructive Testing CY - Metz, France DA - 17.05.2017 KW - Additive manufacturing KW - Ti-6Al-4V KW - Process chain KW - Turbine industry KW - Laser metal deposition PY - 2017 AN - OPUS4-44477 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - CONF A1 - Mishurova, Tatiana A1 - Artzt, Katia A1 - Bruno, Giovanni A1 - Requena, Guillermo A1 - Haubrich, Jan T1 - Subsurface residual stress analysis in Ti-6Al-4V additive manufactured parts by synchrotron x-ray diffraction N2 - Synchrotron X-ray diffraction is a powerful non-destructive technique for the analysis of the material stress-state. High cooling rates and heterogeneous temperature distributions during additive manufacturing lead to high residual stresses. These high residual stresses play a crucial role in the ability to achieve complex geometries with accuracy since they can promote distortion of parts during manufacturing. Furthermore, residual stresses are critical for the mechanical performance of parts in terms of durability and safety. In the present study, Ti-6Al-4V bridge-like specimens were manufactured additively by selective laser melting (SLM) under different laser scanning speed conditions in order to compare the effect of process energy density on the residual stress state. Subsurface residual stress analysis was conducted by means of synchrotron X-ray diffraction in energy dispersive mode for three conditions: as-built on base plate, released from base plate, and after heat treatment on the base plate. The quantitative residual stress characterization shows a correlation with the qualitative bridge curvature method. Computed tomography (CT) was carried out to ensure that no stress relief took place owing to the presence of porosity. CT allows obtaining spatial and size pores distribution which helps in optimization of the SLM process. High tensile residual stresses were found at the lateral surface for samples in the as-built conditions. We observed that higher laser energy density during fabrication leads to lower residual stresses. Samples in released condition showed redistribution of the stresses due to distortion. T2 - 12th ECNDT 2018 CY - Göteborg, Sweden DA - 11.06.2018 KW - Additive manufacturing KW - Selective laser melting KW - Residual stress KW - Synchrotron X-ray diffraction KW - Ti-6Al-4V PY - 2018 UR - http://cdn.ecndt2018.com/wp-content/uploads/2018/05/ecndt-0213-2018-File001.pdf SP - 1 EP - 8 AN - OPUS4-45217 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -