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Optimisation of surface residual stresses using hybrid milling processes for additive manufactured Nickel alloy components

  • Ni alloys are cost intensive materials and generally classified as difficult-to-cut materials. However, machining of these materials is needed especially in case of alloy 36 (1.3912), which is commonly used in mould construction for the production of fibre-reinforced composites. With regard to repair, modification and manufacturing of such components, additive manufacturing offers significant economic advantages. Nevertheless, subsequent machining steps are needed to achieve the final component contour and defined surface conditions. Dependent on the material and machining process conditions, detrimental tensile residual stresses may be the result on the machined surface, having negative impact on the component performance and safety. Recent studies exhibited that hybrid machining processes, such as ultrasonic-assisted milling (USAM), are suitable for achieving favourable residual stress states at the surface of difficult-to-cut Ni-Cr alloys. In this investigation, wire arc additiveNi alloys are cost intensive materials and generally classified as difficult-to-cut materials. However, machining of these materials is needed especially in case of alloy 36 (1.3912), which is commonly used in mould construction for the production of fibre-reinforced composites. With regard to repair, modification and manufacturing of such components, additive manufacturing offers significant economic advantages. Nevertheless, subsequent machining steps are needed to achieve the final component contour and defined surface conditions. Dependent on the material and machining process conditions, detrimental tensile residual stresses may be the result on the machined surface, having negative impact on the component performance and safety. Recent studies exhibited that hybrid machining processes, such as ultrasonic-assisted milling (USAM), are suitable for achieving favourable residual stress states at the surface of difficult-to-cut Ni-Cr alloys. In this investigation, wire arc additive manufactured (WAAM) specimens of alloy 36 were finish milled under different milling conditions. In addition to the machined surfaces condition and topology, the surface-near residual stresses were analysed using X-ray diffraction (XRD). Especially for low cutting speeds, significantly improved surface properties, roughness parameters and lower mechanical and microstructural degradations were found for the specimen machined with USAM compared to conventional milling. The improved surface integrity could furthermore be observed by a significant reduction of the tensile residual stresses in the surface boundary area.zeige mehrzeige weniger

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Metadaten
Autor*innen:Lorenz Engelking
Koautor*innen:A. Eissel, Dirk Schröpfer, K. Treutler, Thomas Kannengießer, V. Wesling
Dokumenttyp:Vortrag
Veröffentlichungsform:Präsentation
Sprache:Englisch
Jahr der Erstveröffentlichung:2022
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.2 Versuchsanlagen und Prüftechnik
9 Komponentensicherheit / 9.4 Integrität von Schweißverbindungen
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Additive manufacturing; Alloy 36; Ni alloy; Surface integrity; Ultrasonic-assisted milling
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Degradation von Werkstoffen
Veranstaltung:Bachelor-, Master-, Doktoranden-Kolloquium, Otto-von-Guericke-Universität Magdeburg
Veranstaltungsort:Magdeburg, Germany
Beginndatum der Veranstaltung:18.05.2022
Enddatum der Veranstaltung:18.05.2022
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:31.05.2022
Referierte Publikation:Nein
Eingeladener Vortrag:Nein
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