5 Werkstofftechnik
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Additive manufacturing (AM) of metallic alloys has gained momentum in the past decade for industrial applications. The microstructures of AM metallic alloys are complex and hierarchical from the macroscopic to the nanometer scale. When using laser-based powder bed fusion (L-PBF) process, two main microstructural features emerge at the nanoscale: the melt pool boundaries (MPB) and the solidification cellular substructure.
Here, details of the MPB are revealed to clearly show the three-dimensional nature of MPBs with changes of cell growth of direction and their relation to their surrounding cellular substructure, as investigated by transmission electron microscopy (TEM) for L-PBF 316L austenitic stainless steel (cf. Figure 1). A hitherto unknown modulated substructure with a period of 21 nm is further discovered within cells as the result of a partial Ga+-focused ion beam-induced ferritic transformation of the austenite. Cell cores and cell boundaries differ notably regarding the modulated substructure.
Metal Additive Manufacturing (AM) technologies such as Laser Powder Bed Fusion (LPBF) are characterized by layer wise construction, which enable advancements of component design, with associated potential gains in performance and efficiency. However, high magnitude residual stresses (RS) are often a product of the rapid thermal cycles typical of the layerwise process. Therefore, a deep understanding of the formation of RS, the influence of process parameters on their magnitude and the impact on mechanical performance is crucial for widespread application. The experimental characterisation of these RS is essential for safety related engineering application and supports the development of reliable numerical models. Diffraction-based methods for RS analysis using neutrons and high energy X-rays enable non-destructive spatially resolved characterisation of both surface and bulk residual stresses in complex components. This presentation will provide an overview of recent research by the BAM at large scale facilities for the characterization of residual stresses in LPBF metallic alloys as a function of process parameters. In addition, the challenges posed by the textured and hierarchical microstructures of LPBF materials on diffraction-based RS analysis in AM materials will be discussed. This will include the question of the d0 reference lattice spacing and the appropriate choice of the diffraction elastic constants (DECs) to calculate the level of RS in LPBF manufactured alloys.
The studied aluminium alloy is EN AW-2618A (2618A). It is very widely used for exhaust gas turbo-charger compressor wheels. Due to long operating times, high cycle fatigue (HCF) and material aging under the influence of temperatures up to 230 °C is particularly relevant for the wheels. The wheels are typically milled from round wrought blanks. From such round blanks, different testpieces are extracted and a comprehensive series of HCF tests is conducted at room temperature. The tests investigate the materials fatigue performance in the T61 state for two load-ratios, namely R = -1 and R = 0.1. Additionally, two overaged material states are tested, accounting for the aging process the material undergoes during long operating times at high temperatures. The experimental results are evaluated and compared to each other.
Furthermore, the design process of notched specimens is presented. With the notched specimens, it is aimed to quantify the notch sensitivity of the material. Relating thereto, two potential model parameters for the fatigue lifetime model are introduced. Finally, the extended research data management in this project is highlighted and its advantages for sustainable use in material science and engineering applications are shown.
To mitigate carbon dioxide emissions CO2 is compressed and sequestrated into deep geological layers (Carbon Capture and Storage CCS). The corrosion of injection pipe steels is induced when the metal is in contact with CO2 and at the same time the geological saline formation water. Stainless steels X35CrMo17 and X5CrNiCuNb16-4 with approximately 17% Cr show potential as injection pipes to engineer the Northern German Basin geological onshore CCS-site. Static laboratory experiments (T = 60 ◦C, p = 100 bar, 700–8000 h exposure time, aquifer water, CO2-flow rate of 9 L/h) were conducted to evaluate corrosion kinetics. The anomalous surface corrosion phenomena were found to be independent of heat treatment prior to exposure. The corrosion process is described as a function of the atmosphere and diffusion process of ionic species to explain the precipitation mechanism and better estimate the reliability of these particular steels in a downhole CCS environment.
Abstract of the event: 'The area of New Space is a vastly growing and dynamic field with a high innovative potential and many exciting ideas. After decades where activities in space were dominated and funded mainly by governmental agencies, a new industry is forming and new business models are being developed around ideas like satellite-based internet, space travel, space mining, geo-monitoring etc. For space applications, lightweight design is crucial to keep the costs at a minimum. This Innovation Day will introduce the field of New Space and present the variety of exciting opportunities that arise for composites based on their excellent lightweight potential.' Another research area is now arising in the field of 3D printing or additive manufacturing of fiber composite materials in space. At the event, we presented on the opportunities and our experiences of using a powder based additive manufacturing process for in-space manufacturing applications.
An investigation of the dislocation substructure and mechanical properties of high-purity niobium single crystals with different initial crystal orientations deformed in tension at strain rates of 10^{-4} to 10^3 s^{-1} is presented. Specimens were cut from a large grain niobium disk used for the manufacturing of SRF cavities. Different crystallographic tensile directions exhibited significantly different softening and hardening behaviors and elongation at fracture. Such anisotropy is reduced at high strain rates. Also, different dislocation substructures were observed with TEM at low and high strain rates. At low strain rates, dislocation cells with a high density of long dislocations were observed. At high strain rates, homogeneously distributed dislocations with a higher dislocation dipole density were observed. The relationship between the differences in dislocation substructures and mechanical properties at low and high strain rates and the potential effects on the superconducting properties are discussed.
Roughening of zirconia dental implants is a common clinical practice to improve ingrowth behavior. It depends on the manufacturer of the implant at which stage of the manufacturing process and by which method the surface is roughened. Systematic studies on this topic are rarely found in the literature. Therefore, the influence of surface treatment on the strength of a dental zirconia was investigated as part of a research project on the development of ceramic implants. The material under test was a commercial zirconia consisting of a Y-TZP matrix and Ce-TZP inclusions in the sintered state. This material is characterized by a slightly higher fracture toughness and slightly reduced strength compared to typical 3Y-TZP. Sets of samples were sandblasted in the white-fired or sintered condition. The ball-on-three-ball-strength of these samples was measured and compared to the strength of as-fired samples and polished samples. The complete study was performed two times for validation of the results. It is found that the average strength of TZP ceramics differs by almost 500 MPa depending on the surface treatment. Conventionally sintered specimens with as-fired surface exhibit a strength of 880 MPa. Sandblasting in the white fired state reduces the strength to 690 MPa. Both polishing and sandblasting in the sintered condition result in an increase in strength to about 1180 MPa. Comparative microstructural investigations, roughness measurements and X-ray phase analyses were carried out to determine the causes of these huge differences in strength. These findings may challenge the practice of white body surface treatment and give reason for further investigations on other commercial dental TZP materials.
In-space manufacturing (ISM) provides the opportunity to manufacture and repair critical components on future human spaceflight missions. For explorations to Mars and beyond, ISM is a key strategy not only due to the long travel distances and high costs of supply from earth but also to be able to safely work in space for years. Human spaceflight is still dependent on shipments from earth that can fail for several reasons. ISM is a valuable alternative to ensure the timely and safe resupply of space missions.
With additive manufacturing (AM) technologies, components are built directly from a 3D computer-aided-design (CAD) model which offers the advantages of freedom of design and the production of complex and ready-to-use parts. A virtual tool box with 3D models in space or the supply of information instead of components from earth to space can strongly benefit future missions. For industrial use, most research has focused on laser based additive manufacturing processes such as laser beam melting (LBM) where metallic powder particles are spread into a uniform powder bed and melted by a laser to the desired shape.
In the absence of gravity, the handling of metal powders, which is essential for the process, is challenging. We present an evolution of an AM system, where a gas flow throughout the powder bed is applied to stabilize the powder bed. This is needed to compensate for the missing gravitational forces in microgravity experiments on parabolic flight campaigns. The system consists of a porous building platform acting as a filter for the fixation of metal particles in a gas flow. It is driven by reduced pressure established by a vacuum pump underneath the platform. The system creates a drag force that directs the particles towards the porous building platform, similar to the effect of the gravitational force.
The AM system with its gas-flow-assisted powder deposition has been tested in several parabolic flight campaigns, and stainless-steel powder has successfully been processed during microgravity conditions. Different powder recoating mechanisms have been investigated to assess the homogeneous distribution of the powder as well as the attachment of the next layer to the powder bed. These mechanisms included different container designs with parallel double blades and with a V-shape at the bottom, and a roller recoating system. The samples presented are the first metal parts ever manufactured using LBM in μ-gravity. In addition to manufacturing in a μ-gravity environment, the experiments have shown the feasibility to manufacture components at different accelerations during the parabolic flight: hyper gravity (1.8 g), μ-gravity (< 0.01 g) and 1 g. Recent results will also be presented describing the application of this LBM setup in a parabolic flight campaign with mixed lunar, martian and µ-gravity acceleration, during which the processing of a lunar regolith simulant powder was tested.
For ISM, the development and testing of the proposed AM system demonstrates that LBM can be considered a viable technology for the manufacturing of metal and ceramic parts in a μ-gravity or reduced-gravity environment.
Additive manufacturing (AM) processes are opening new design possibilities for large scale electrical devices such as power generators. Conventional manufacturing methods use copper rods which are wrapped, vacuum impregnated, bend and welded. These processes are labor-intensive and time-consuming. The introduction of AM methods for manufacturing the copper conductor and electrical insulation can reduce the size of the generator head, the most complex part of the generator.
In this study, the electrical and dielectrical properties of additively deposited ceramic layers are investigated and compared with the properties of conventionally fabricated bulk ceramics. The ceramic layers are thermally deposited by atmospheric plasma spraying of a commercially available alumina powder. Bulk ceramics are fabricated by dry pressing and sintering of the same powder. Microstructure and porosity were analyzed by scanning electron microscopy (SEM). Electrical and dielectrical properties such as DC resistance, dielectric strength, dielectric loss, and relative permittivity were determined according to the standards.
The microstructures of sprayed and sintered alumina show significant differences with respect to grain form and porosity. The density of the bulk ceramic is lower than the density of the sprayed layer due to the coarse particle size (d50 = 33 μm). Therefore, data from dense samples of the same chemical composition but lower particle size alumina powder were used for comparison.