Ingenieurwissenschaften und zugeordnete Tätigkeiten
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Eingeladener Vortrag
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Additive manufacturing (AM) of alkali-activated materials is a promising method for producing ceramic precursors, construction elements and other parts. A recently introduced AM process is laser-induced slip casting of lithium aluminate/microsilica slurries, which yields parts with excellent mechanical strengths. To clarify the underlying mechanisms, μ-Raman spectroscopy was applied to parts produced by the process, and the dissolution and hydration of lithium aluminate was studied inter alia using conventional and in-situ X-ray diffraction. The results show that significant dissolution of lithium aluminate occurs, particularly at increased temperatures during laser interaction, which leads to an increase of pH and precipitation of an akopovaite-like Li-Al-CO3 layered double hydroxide. The increase of the pH is likely to induce dissolution of the microsilica and possibly formation of a hydrous lithium aluminosilicate gel. These observations explain the strength evolution of the studied parts and can also aid the development and improvement of related AM methods.
The quality of additively manufactured components is significantly influenced by the process parameters used during production. Thus, sensors and measuring systems are already commercially available for process monitoring, at least in metal-based additive manufacturing. However, it is not yet possible to detect defects and inhomogeneities directly or indirectly during the building process. The aim of the project ProMoAM is to develop spectroscopic and non-destructive testing methods for the in-situ evaluation of the quality of additively manufactured metal components in laser- or arc-based AM processes. In addition to passive and active methods of thermography, this includes optical tomography, optical emission spectroscopy, eddy current testing, laminography (radiography), X-ray backscattering, particle emission spectroscopy and photoacoustic methods.
Ti-6Al-4V alloy is intensively used in the aerospace industry because of its high specific strength. However, the application of Laser Powder Bed Fusion (LPBF) Ti-6Al-4V alloy for structurally critical load-bearing components is limited. One of the main limiting factors affecting the structural integrity, are manufacturing defects. Additionally, the high cooling rates associated with LPBF process result in the formation of large residual stress (RS) with complex fields. Such RS can cause cracking and geometrical distortions of the part even right after production. Also, the microstructure of LPBF Ti-6Al-4V in the as-built condition is significantly different from that of the conventionally produced alloy. All these factors affect the mechanical behavior of the material. Therefore, to improve the material performance it is important to evaluate the individual effect of RS, defects, and microstructure on fatigue life. To this aim Ti-6Al-4V LPBF material in as-built condition and subjected to different post-processing, including two heat treatments (for stress relief and microstructural modification) and Hot Isostatic Pressing (HIP, for densification), were investigated.
Prior to fatigue tests at elevated temperature, the microstructure, the mesostructure, and subsurface RS on the fatigue samples were investigated. It was found that the fatigue performance of HIPped samples is similar to that of conventionally produced Ti-6Al-4V. The tensile RS found at the surface of as-built samples decreased the fatigue life compared to heat-treated samples. Additionally, the modification of the microstructure (by heat treatment) did not affect the fatigue performance in the regime of mostly elastic strain. 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.
Additive manufacturing (AM) technologies are experiencing an exceedingly rapid growth, driven by their potential through layer wise deposition for transformational improvements of engineering design, leading to efficiency and performance improvements. Laser Powder Bed Fusion (LPBF) is an Additive Manufacturing (AM) method which permits the fabrication of complex structures that cannot otherwise be produced via conventional subtractive manufacturing methods. Nevertheless, the rapid cooling rates associated with this process results in the formation of significant and complex residual stress (RS) fields. A large body of both experimental and simulation research has been dedicated in recent years to the control and mitigation of RS in AM. In order to validate simulations with the end goal of being able to model the residual stress state in AM components and to devise strategies for their reduction during manufacturing, experimental methods need to be able to accurately determine 3D residual stresses fields in complex geometries. Several destructive and non-destructive methods can be used to analyze the RS state, the choice of which depends on the geometry and the information required. Diffraction-based methods using penetrating neutron and synchrotron X-rays at large scale facilities offer the possibility to non-destructively spatially resolve both surface and bulk residual stresses in complex components and track their changes following applied thermal or mechanical loads. This presentation will overview the success stories of using large scale facilities by the BAM for the characterization of residual stresses in additively manufactured metallic alloys. In particular, the study of the influence of process parameters on the residual stress state and the relaxation of these stresses through heat treatment will be presented. However there remains challenges to overcome particularly of the hypotheses underlying the experimental determination of residual stresses, which will be discussed.
Metal Additive manufacturing (AM) technologies such as Laser Powder Bed Fusion (LPBF) enable the fabrication of complex structures, giving rise to potential improvements in component and manufacturing efficiency. However, the processes are typically characterized by the generation of high magnitude residual stress (RS) which can have detrimental consequences for subsequent applications. Therefore, the characterization of these RS fields and the understanding of their formation and mitigation through optimized processing is crucial for the wider uptake of the technology. Due to the potential complex nature and high value of components manufactured by LPBF, it is important to have suitable characterisation methods which can determine the spatial variations of RS in a non-destructive manner. Neutron diffraction is considered to be the best suited for these requirements. However, the microstructures developed in the complex thermal cycles experience in the production can pose challenges to the ND method for RS analysis. The BAM has conducted significant research over the past years to overcome these obstacles, enabling higher confidence in the RS determined in LPBF materials by neutron diffraction. This contribution will overview some of these advancements made recently at European neutron sources including on Stress-Spec at FRM2/MLZ.
Additive manufacturing is well established for plastics and metals, and it gets more and more implemented in a variety of industrial processes. Beside these well-established material platforms, additive manufacturing processes are highly interesting for ceramics, especially regarding resource conservation and for the production of complex three-dimensional shapes and structures with specific feature sizes in the µm and mm range with high accuracy. The usage of ceramics in 3D printing is, however, just at the beginning of a technical implementation in a continuously and fast rising field of research and development. The flexible fabrication of highly complex and precise 3D structures by means of light-induced photopolymerization that are difficult to realize using traditional ceramic fabrication methods such as casting and machining is of high importance. Generally, slurry-based ceramic 3D printing technologies involve liquid or semi-liquid polymeric systems dispersed with ceramic particles as feedstock (inks or pastes), depending on the solid loading and viscosity of the system. This paper includes all types of photo-curable polymer-ceramic-mixtures (feedstock), while demonstrating our own work on 3D printed alumina toughened zirconia based ceramic slurries with light induced polymerization on the basis of two-photon absorption (TPA) for the first time. As a proven exemplary on cuboids with varying edge length and double pyramids in the µm-range we state that real 3D micro-stereolithographic fabrication of ceramic products will be generally possible in the near future by means of TPA. This technology enables the fabrication of 3D structures with high accuracy in comparison to ceramic technologies that apply single-photon excitation. In sum, our work is intended to contribute to the fundamental development of this technology for the representation of oxide-ceramic components (proof-of-principle) and helps to exploit the high potential of additive processes in the field of bio-ceramics in the medium to long-term future.
Nickel-iron-alloy modification to enhance additively welded microstructure for subsequent milling
(2021)
The aerospace industry uses nickel-iron-alloys to create moulding tools for composite materials because of the low coefficient of thermal expansion. These tools have a large-sized and complex structure, making them cost-intensive and difficult to manufacture. Therefore, the focus is set on additive manufacturing, which can additionally enable the repair of components in order to eliminate local defects. However, the process usually results in a heterogeneous microstructure and anisotropic mechanical properties. As there is a high demand for a precise and exact fit of the precision moulds and thus the surface quality, the welded components must be subsequently machined. Nickel-iron alloys are difficult to machine and an inhomogeneous microstructure also leads to unstable cutting forces.
Consequently, a refinement and homogenisation of the microstructure morphology is achieved through specific alloy modifications in order to stabilise and improve the subsequent machining process. Studies on the refinement of FeNi 36 based on vacuum arc melting furnaces are used as a starting point. Therefore, titanium and niobium are chosen as modification elements with a maximum 1 % weight percent and are added to nickel-iron base alloy. The elements are alloyed and build-up welded by using plasma-transferred-arc welding. The resulting microstructure morphology of the welded wall structure and the machining properties are then determined. Furthermore, the influence on the coefficient of thermal expansion is investigated in connection with the modification and the welding process itself. It can be shown that even small amounts of niobium have a significant influence on the structural morphology of the welded layers during plasma-transferred-arc welding.
Due to increasing requirements relating to the efficiency of highly stressed components in turbine or plant construction, the use of cost-intensive, difficult to process materials is increasingly necessary today. In this context, cobalt-chromium alloys in particular are highly resistant to thermal and mechanical stress, as well as to corrosive and abrasive loads. Moreover, increasingly complex structures and the optimisation of resource efficiency also require additive manufacturing steps for the production or repair of components in many sectors. In order to realise a homogeneous and isotropic microstructure, alloy modifications are made to the alloy CoCr26Ni9Mo5W. For this purpose, hafnium and zirconium are added at 1 % and 0,33 % by mass each, as these elements are supposed to have a positive effect on the microstructure morphology. Plasma-Transferred-Arc is used for the welding tests. Wall structures are welded by multiple single-layer, overlapping welding beads on low-alloyed steel substrate (S355). The results show that the alloying elements hafnium and zirconium have a clear influence on the microstructure. Hardness measurements were also carried out. With each modification, the hardness is increased compared to the original material. The machining analyses show a reduction in cutting forces using ultrasonic assisted milling for high cutting speed and low feed rate.
The underlying cause of mechanical anisotropy in additively manufactured (AM) parts is not yet fully understood and has been attributed to several different factors like microstructural defects, residual stresses, melt pool boundaries, crystallographic and morphological textures.
To better understand the main contributing factor to the mechanical anisotropy of AM stainless steel 316L, bulk specimens were fabricated via laser powder bed fusion (LPBF).
Tensile specimens were machined from these AM bulk materials for three different inclinations relative to the build plate. Dynamic Young's modulus measurements and tensile tests were used to determine the mechanical anisotropy. Some tensile specimens were also subjected to residual stress measurement via neutron diffraction, porosity determination with X-ray micro-computed tomography, and texture analysis with electron backscatter diffraction (EBSD). A crystal plasticity model was used to analyze the elastic anisotropy and the anisotropic yield behavior of the AM specimens, and it was able to capture and predict the experimental behavior accurately. Overall, it was shown that the mechanical anisotropy of the tested specimens was mainly influenced by the crystallographic texture.