Developing Gradient Metal Alloys through Radial Deposition Additive Manufacturing

Hofmann, Douglas C.; Roberts, Scott; Otis, Richard; Kolodziejska, Joanna A.; Dillon, R. Peter; Suh, Jong Ook; Shapiro, Andrew A.; Liu, Zhe; Borgonia, John Paul

doi:10.1038/srep05357

Cited by 250 publications

(94 citation statements)

References 26 publications

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“…At present, manufacturing such functionally tailored structures by the existing fusion-based AM processes is a challenge because of the differential thermal expansion coefficients of two alloys/materials that need to be fused. In cases, where this challenge is circumvented, avoiding undesirable intermetallic formation becomes a key issue (Hofmann et al, 2014). Since FBAM operates in solid state, the concern for thermal expansion is completely avoided while the intensified shearing during the process aids in controlling the size and distribution of intermetallics at the interface.…”

Section: Scope Of Friction-based Additive Technologiesmentioning

confidence: 99%

Building without melting: a short review of friction-based additive manufacturing techniques

Palanivel¹,

Mishra²

2017

IJASMM

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Fusion additive technologies have pushed the boundaries beyond what was previously envisaged in the metal community. Championed by laser-based and electron beam technologies, metal additive manufacturing has captivated the interests of aerospace, defence, energy, automotive, and medical sectors. Though game-changing, these fusion-based techniques suffer from solidification related issues which play a critical role in applications where high premium is placed on materials' performance. Furthermore, only limited number of alloys can be built due to complexities associated with melting. To address these drawbacks, parallel work on solid state technologies was initiated in the last decade. An outcome of these efforts has been the development of additive manufacturing technologies based on friction which has now reached a stage where compilation is possible. In this article, fundamental principle and features of these friction-based additive technologies are reviewed with special emphasis on their individual advantages and differences between them. In addition, further scope, challenges and potential of these technologies are highlighted.Keywords: fusion additive technologies; metal additive manufacturing; solid state; friction-based additive manufacturing; FBAM; material performance. After undergraduate studies, he joined the Center for Friction Stir Processing and works with Dr. Rajiv Mishra. His research interests include additive manufacturing, physical metallurgy of Al and Mg alloys, alloy design using Calphad approach and field effects on microstructure. In the field of additive manufacturing, he has the first few publications on friction stir additive manufacturing and has also published on fusion additive manufacturing linking site dependent properties to microstructure.

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Section: Scope Of Friction-based Additive Technologiesmentioning

confidence: 99%

Building without melting: a short review of friction-based additive manufacturing techniques

Palanivel¹,

Mishra²

2017

IJASMM

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“…For polymers, such systems have been demonstrated in inkjet 3D printing 23 ; for metals, such systems have been demonstrated in directed energy deposition, especially in laser engineered net shaping (LENS). [31][32][33][34] The right side shows a second type of mesoscale heterogeneous material systems, where each material voxel is assigned to be a specific constituent material. Such a material system can be fabricated by multi-nozzle extrusion, 35,36 inkjet 3D printing, 37,38 or directed energy deposition.…”

Section: Introductionmentioning

confidence: 99%

“…Such a material system can be fabricated by multi-nozzle extrusion, 35,36 inkjet 3D printing, 37,38 or directed energy deposition. [31][32][33][34] Since multi-material additive manufacturing provides a unique pathway to implementing an arbitrary mesoscale material distribution, Yu, Cross, and Schuh 39 proposed to use computational optimization schemes for mesostructure design. By investigating the resistance to contact loading and bending as examples, they showed that significant improvement in material efficiency, load bearing capacity, and weight saving can be achieved by properly distributing the mechanical properties across the component.…”

Section: Introductionmentioning

confidence: 99%

“…Thanks to the recent progress in advanced manufacturing, especially multi-material additive manufacturing, [23][24][25][26][27] mesostructure control is becoming available for a wide variety of materials, including polymers, metals, and composites. [28][29][30][31][32] Figure 1 shows two types of mesoscale heterogeneous material systems readily fabricated by multi-material additive manufacturing. The left side shows a material system with gradient properties by mixing multiple constituent materials and controlling the volume ratios.…”

Section: Introductionmentioning

confidence: 99%

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Mesoscale design of heterogeneous material systems in multi-material additive manufacturing

et al. 2017

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Mesoscale heterogeneous material systems are efficient and adaptive to real world environments, owing to the non-uniform stress fields that result from the convolution of component geometries, loading conditions, and environmental changes. With the advent of multi-material additive manufacturing, the production of heterogeneous material systems with a pre-defined mesoscale material distribution becomes feasible. This unlocks the design freedom at a characteristic length scale between the macroscale geometry and microstructures, but also calls for a new design framework to optimize the mesoscale material distribution in multi-material additive manufacturing. Here, we propose and demonstrate such a design framework by incorporating digital image correlation-based deformation mapping with 3D finite element modeling-based computational optimization. The constitutive behavior of each constituent material or their mixtures is calibrated by matching the local deformation data. The optimal mesoscale material distribution can then be determined using global optimization algorithms and validated experimentally.

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“…Motivated by the increased application potential, and inspired from accessible published research in the more established associated fields of joining (e.g. welding) of dissimilar metals and manufacturing of functional graded materials, forays have already been made into additive manufacturing of multi-metal components by a few research groups [4] [5] [6] [7] [8]. However, additively manufactured multi-metal components are currently limited to research samples, primarily due to challenges in understanding, characterizing and controlling the involved manufacturing processes.…”

Section: Introductionmentioning

confidence: 99%

Laser additive manufacturing of multimaterial tool inserts: a simulation-based optimization study

Mohanty

Hattel

2017

SPIE Proceedings

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Selective laser melting is fast evolving into an industrially applicable manufacturing process. While components produced from high-value materials, such as Ti6Al4V and Inconel 718 alloys, are already being produced, the processing of multi-material components still remains to be achieved by using laser additive manufacturing. The physical handling of multi-material in a SLM setup continues to be a primary challenge along with the selection of process parameters/plan to achieve the desired results -both challenges requiring considerable experimental undertakings. Consequently, numerical process modelling has been adopted towards tackling the latter challenge in an effective manner.In this paper, a numerical simulation based optimization study is undertaken to enable selective laser melting of multi-material tool inserts. A standard copper specimen covered by a thin layer of nickel is chosen, over which a layer of steel has been deposited using cold-spraying technique, such as to protect the microstructure of Ni during selective laser melting. The process modelled thus entails additively manufacturing a steel tool insert around the multi-material specimen with a goal of achieving a dense product while preventing recrystallization in the Nickel layer. The process is simulated using a high-fidelity thermo-microstructural model with constant processing parameters to capture the effect on Nickel layer. Based on results, key structural and process parameters are identified, and subsequently an optimization study is conducted using evolutionary algorithms to determine the appropriate process parameter values as well as processing sequence. The optimized process plan is then used to manufacture real multi-material tool insert samples by selective laser melting.

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Developing Gradient Metal Alloys through Radial Deposition Additive Manufacturing

Cited by 250 publications

References 26 publications

Building without melting: a short review of friction-based additive manufacturing techniques

Building without melting: a short review of friction-based additive manufacturing techniques

Mesoscale design of heterogeneous material systems in multi-material additive manufacturing

Laser additive manufacturing of multimaterial tool inserts: a simulation-based optimization study

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