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Directed energy deposition additive manufactured parts have steep stress gradients and an anisotropic microstructure caused by the rapid thermo-cycles and the layer-upon-layer manufacturing, hence heat treatment can be used to reduce the residual stresses and to restore the microstructure. The numerical simulation is a suitable tool to determine the parameters of the heat treatment process and to reduce the necessary application efforts. The heat treatment simulation calculates the distortion and residual stresses during the process. Validation experiments are necessary to verify the simulation results. This paper presents a 3D coupled thermo-mechanical model of the heat treatment of additive components. A distortion-based validation is conducted to verify the simulation results, using a C-ring shaped specimen geometry. Therefore, the C-ring samples were 3D scanned using a structured light 3D scanner to compare the distortion of the samples with different post-processing histories.
Components distort during directed energy deposition (DED) additive manufacturing (AM) due to the repeated localised heating. Changing the geometry in such a way that distortion causes it to assume the desired shape – a technique called distortion-compensation – is a promising method to reach geometrically accurate parts. Transient numerical simulation can be used to generate the compensated geometries and severely reduce the amount of necessary experimental trials. This publication demonstrates the simulation-based generation of a distortioncompensated DED build for an industrial-scale component. A transient thermo-mechanical approach is extended for large parts and the accuracy is demonstrated against 3d-scans. The calculated distortions are inverted to derive the compensated geometry and the distortions after a single compensation iteration are reduced by over 65%.
Das DED Auftragschweißen ist ein additives Fertigungsverfahren für Metalle, bei dem das Material schichtweise auf ein Substrat aufgetragen wird. Die schnellen Temperaturzyklen rufen Spannungsgradienten im Bauteil hervor. Der schichtweise Aufbau der Bauteile verursacht eine anisotrope Mikrostruktur. Mittels nachgelagerter Wärmebehandlung können diese Effekte verringert werden. Im anschließenden Schritt der Prozesskette wird das additiv hergestellte Bauteil mittels Drahterodieren von dem Substrat abgetrennt.
In diesem Beitrag wird eine thermo-mechanische Simulation der gesamten Prozesskette vorgestellt, welche den additiven Aufbau, Wärmebehandlung und das Abtrennen vom Substrat beinhaltet. Anstelle der in der Literatur üblichen schichtweisen Modellierungsstrategie für die DED Simulation wird das gesamte Bauteil in einem Stück vernetzt und der vollständig transiente, schichtweise Materialauftrag über Elementgruppen realisiert. Im Gegensatz zu früheren Simulationen muss der nichtlineare Kontakt zwischen den Schichten nicht berücksichtigt werden, was die Rechenzeiten deutlich verkürzt.
Das Modell wurde validiert mittels Abgleiches des Verzugs aus Simulation und Experiment.
Die Proben, bestehend aus DIN 1.4404 (AISI 316L), wurden nach jedem Prozessschritt 3D gescannt um den Verzug zu quantifizieren. Zusätzlich wurden Querschnitte und Härtetests nach Vickers von unterschiedlich behandelten Proben durchgeführt, um den Effekt der Wärmebehandlung auf die Mikrostruktur und die Härte des Bauteils zu untersuchen.
The neutron time-of-flight spectrometer NEAT has a long history of successful applications and is best suited to probe dynamic phenomena directly in the large time domain 10(-14) - 10(-10) s and on the length scale ranging from 0.05 to up to about 5 nm. To address user community needs for more powerful instrumental capabilities, a concept of the full upgrade of NEAT has been proposed. The upgrade started in 2010 after a rigorous internal and external selection process and resulted in 300-fold neutron count rate increase compared to NEAT01995. Combined with new instrumental and sample environmental capabilities the upgrade allows NEAT to maintain itself at the best world class level and provide an outstanding experimental tool for a broad range of scientific applications. The advanced features of the new instrument include an integrated guide-chopper system that delivers neutrons with flexible beam properties: either highly homogeneous beam with low divergence suitable for single crystals studies or "hot-spot" neutron distribution serving best small samples. Substantial increase of the detector angle coverage is achieved by using 416 He-3 position sensitive detectors. Placed at 3m from the sample, the detectors cover 20m(2) area and are equipped with modern electronics and DAQ using event recording techniques. The installation of hardware has been completed in June 2016 and on January 23, 2017 NEAT has welcomed its first regular users who took advantage of the high counting rate, broad available range of incoming neutron wavelengths and high flexibility of NEAT. Here we present details of NEAT upgrade, measured instrument characteristics and show first experimental results.
Surface Properties and Porosity of Silica Particles Studied by Wide-Angle Soft X-ray Scattering
(2020)
Wide-angle soft X-ray scattering on free silica particles of different porosity prepared in a beam is reported. The explored q region is mostly dominated by features due to surface roughness and bulk porosity. A comprehensive experimental and theoretical analysis of silica particles of different porosity is presented for various incident photon energies. A correlation analysis, based on the theory of Porod, is used to test the validity of exact Mie theory in different pore density limits. The ability of the discrete dipole scattering model (DDSCAT) to resolve local effects, caused by various pore distributions, is discussed. Characteristic differences between the soft X-ray scattering patterns of the particle samples of different surface properties and porosity are detected. For all mentioned cases, it was confirmed that the effective radius concept of the Guinier model can be successfully extended to Mie theory and DDSCAT in describing the additive contributions of the primary particles, including a thin inhomogeneous solvent-rich surface shell and empty bulk pores. Close agreement, within ±15%, between the calculated and observed pore sizes and porosity values is reached. The influence of pores is alternatively described either in terms of secondary Mie scattering, which is modulated by the local internal electrical field within the particles, or by an independent Mie scattering process induced by the incident field on isolated pores. It is found that for the typical pore/particle size ratios the latter approach presents the best choice.
Komplexe Bauteile ohne Fügestellen sind die Spezialität additiver Verfahren. Immer deutlicher wird der Wert dieser Technologie für den Turbomaschinenbau, etwa bei der Fertigung von Turbinenschaufeln mit inneren Kühlstrukturen. Wichtig für vorbildgetreue Turbinenkomponenten: Die Technologie ermöglicht die Fertigung von Freiformen und Hinterschnitten, von außen- und innenliegenden filigranen, komplexen Strukturen als Einzelteil - und das in einem einzigen Arbeitsschritt. Des Weiteren benötigen additive Verfahren keine formgebenden Werkzeuge und weisen demnach kürzere Prozessketten im Vergleich zu konventionellen Herstellungsverfahren auf. Wirtschaftliche Vorteile kommen vor allem bei kleinen Losgrößen und Bauteilabmessungen zur Geltung.
In diesem Artikel werden am Beispiel einer Turbinenschaufel Schlüsseltechnologien einer additiven Prozesskette gezeigt. Zunächst erfolgt die additive Fertigung einer Turbinenschaufel mittels Selective Laser Melting (SLM). Das Verfahren ermöglicht die Integration innenliegender Kühlkanäle. An dieser Schaufel wird anschließend mittels Laser-PulverAuftragschweißen (LPA) die Reparatur unterschiedlicher Beschädigungen demonstriert. Im nächsten Schritt der Prozesskette bietet ein optischer 3D-Scan der Schaufel die Möglichkeit zur Qualitätskontrolle und zum Vergleich der Bauteilabmessungen mit der Sollgeometrie.
Design of experiments for laser metal deposition in maintenance, repair and overhaul applications
(2013)
Modern and expensive parts lead to an increasing demand for maintenance, repair and overhaul (MRO) technologies. Instead of part replacement, MRO technologies are economically advantageous throughout the life cycle. Laser metal deposition as modern MRO technology can be used to repair cracks or protect damaged surfaces with a hard facing layer. It is necessary to adjust weld bead profile to the specific task. For this purpose, Design of Experiment (DoE) has a high potential to decrease experimental effort. In this paper, a full factorial design is used to determine the effect of process parameters on the geometric dimensions of the weld bead. The paper is of interest to engineers working with laser metal deposition as well as DoE methods.
Self-assembled monolayers of aromatic omega-aminothiols on gold: surface chemistry and reactivity
(2010)
Amino-terminated self-assembled monolayers on gold substrates were studied by X-ray photoelectron spectroscopy (XPS), near-edge X-ray absorption fine structure (NEXAFS) measurements, and atomic force microscopy (AFM). Two different ω-amino-4,4'-terphenyl substituted alkanethiols of the general structure H2N-(C6H4)3-(CH2)n-SH (ATPn) were used: 2-(4''-amino-1,1':4',1''-terphenyl-4-yl)ethane-1-thiol (n = 2, ATP2) and 3-(4''-amino-1,1':4',1''-terphenyl-4-yl)propane-1-thiol (n = 3, ATP3). Moreover, the addressability of amino groups within the films was investigated by chemical derivatization of ATPn SAMs with 3,5-bis(trifluoromethyl)phenyl isothiocyanate (ITC) forming fluorinated thiourea ATPn-F films. Evaluation of high-resolution C 1s and N 1s XPS data revealed successful derivatization of at least 50% of surface amino species. Furthermore, it could be demonstrated by angle-resolved NEXAFS spectroscopy that chemical derivatization with ITC has no noticeable influence on the preferential upright orientation of the molecules in the SAMs.
size limitations and high production costs of L-PBF make it competitive for smaller, highly complex components, while the less complex elements of an assembly are manufactured conventionally. This leads to scenarios that use L-PBF only where it’s beneficial, and it require an integration and joining to form the final product. For example, L-PBF combustion swirlers are welded onto cast parts to produce combustion systems for stationary gas turbines. Today, the welding process requires complex welding fixtures and tack welds to ensure the correct alignment and positioning of the parts for repeatable weld results. In this paper, L-PBF and milled weld preparations are presented as a way to simplify the Tungsten inert gas (TIG) welding of rotationally symmetrical geometries using integrated features for alignment and fixation. Pipe specimens with the proposed designs are manufactured in Inconel 625 using L-PBF and milling. The pipe assembly is tested and TIG welding is performed for validation. 3D scans of the pipes before and after welding are evaluated, and the weld quality is examined via metallography and computed tomography (CT) scans. All welds produced in this study passed the highest evaluation group B according to DIN 5817. Thanks to good component alignment, safe handling, and a stable welding process, the developed designs eliminate the need for part-specific fixtures, simplify the process chain, and increase the process reliability. The results are applicable to a wide range of components with similar requirements.