Development of Al-TiC Wire Feedstock for Additive Manufacturing by Metal Screw Extrusion

Langelandsvik, Geir; Grandcolas, Mathieu; Skorpen, Kristian Grøtta; Furu, Trond; Akselsen, Odd M.; Roven, Hans Jørgen

doi:10.3390/met10111485

Cited by 10 publications

(8 citation statements)

References 28 publications

(42 reference statements)

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“…Based on the metal screw extrusion principle [ 195 ], fragmented aluminum pieces were mixed with ceramic nanoparticle powder into a ’mincer’ driven by an Archimedes screw. The individual fragments were consolidated to a single volume, compressed, and extruded as a wire [ 196 ]. The torsional component of the screw motion dispersed the nanosized reinforcement phase without excessive agglomeration.…”

Section: Aluminum Alloys For Waammentioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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Processing of aluminum alloys by wire arc additive manufacturing (WAAM) gained significant attention from industry and academia in the last decade. With the possibility to create large and relatively complex parts at low investment and operational expenses, WAAM is well-suited for implementation in a range of industries. The process nature involves fusion melting of a feedstock wire by an electric arc where metal droplets are strategically deposited in a layer-by-layer fashion to create the final shape. The inherent fusion and solidification characteristics in WAAM are governing several aspects of the final material, herein process-related defects such as porosity and cracking, microstructure, properties, and performance. Coupled to all mentioned aspects is the alloy composition, which at present is highly restricted for WAAM of aluminum but received considerable attention in later years. This review article describes common quality issues related to WAAM of aluminum, i.e., porosity, residual stresses, and cracking. Measures to combat these challenges are further outlined, with special attention to the alloy composition. The state-of-the-art of aluminum alloy selection and measures to further enhance the performance of aluminum WAAM materials are presented. Strategies for further development of new alloys are discussed, with attention on the importance of reducing crack susceptibility and grain refinement.

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Section: Aluminum Alloys For Waammentioning

confidence: 99%

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

et al. 2021

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“…The quality of the feedstock is of utmost importance, as porosity in the feedstock stock powders has been shown to drastically increase the porosity of the printed part [91]. Poor surface quality and diameter variances of wire feedstock can trap moisture and hydrocarbon residue during the deposition process, resulting in porosity in the final deposit [215][216][217][218]. This section of the report will outline the common materials and the as-built microstructures found in the above-mentioned AM techniques, as shown in Table 2 and Table 3.…”

Section: Methodsmentioning

confidence: 99%

Large-scale metal additive manufacturing: a holistic review of the state of the art and challenges

Lehmann

Rose

Ranjbar

et al. 2021

International Materials Reviews

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Additive Manufacturing (AM) has the potential to completely reshape the manufacturing space by removing the geometrical constraints of commercial manufacturing and reducing component lead time, especially for large-scale parts. Coupling robotic systems with direct energy deposition (DED) additive manufacturing techniques allow for support-free printing of parts where part sizes are scalable from sub-metre to multi-metre sizes. This paper offers a holistic review of large-scale robotic additive manufacturing, beginning with an introduction to AM, followed by different DED techniques, the compatible materials and their typical as-built microstructures. Next, the multitude of robotic build platforms that extend the deposition from the standard 2.5 degrees of freedom (DOF) to 6 and 8 DOF is discussed. With this context, the decomposition and slicing of the computerized model will be described, and the challenges of planning the deposition trajectory will be discussed. The different modalities to monitor and control the deposition in an attempt to meet the geometrical and performance specifications are outlined and discussed. A wide range of metals and alloys have been reported and evaluated for large-scale AM parts. These include steels, Ti, Al, Mg, Cu, Ni, Co-Cr and W alloys. Different post-processing steps, including heat treatments, are discussed, along with their microstructures. This paper finally addresses the authors' perspective on the future of the field and the largest knowledge gaps that need to be filled before the commercial implementation of robotic AM.

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“…The novel metal screw extrusion (MSE) method will be used to produce the feedstock material for WAAM. MSE provides a solid-state alternative for manufacturing of aluminium matrix composites with low degree of agglomeration and high versatility in terms of using different alloys and ceramic reinforcements [14].…”

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confidence: 99%

Wire arc additive manufacturing of AA5183 with TiC nanoparticles

Langelandsvik

Eriksson

Akselsen

et al. 2021

Int J Adv Manuf Technol

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Aluminium alloys processed by wire arc additive manufacturing (WAAM) exhibit a relatively coarse microstructure with a columnar morphology. A powerful measure to refine the microstructure and to enhance mechanical properties is to promote grain refinement during solidification. Addition of ceramic nanoparticles has shown great potential as grain refiner and strengthening phase in aluminium alloys. Thus, an Al-Mg alloy mixed with TiC nanoparticles was manufactured by the novel metal screw extrusion method to a wire and subsequently deposited by WAAM. Measures to restrict oxidation of magnesium during metal screw extrusion were examined. Purging of CO2 gas into the extrusion chamber resulted in a remarkable reduction in formation of MgO and Mg(OH)2. TiC decomposed to Al3Ti during WAAM deposition, leading to a significant grain refinement of 93% compared to a commercial benchmark. The presence of remaining TiC nanoparticles accounted for an increased hardness of the WAAM material through thermal expansion mismatch strengthening and Orowan strengthening. Exposure of TiC to moisture in air during metal screw extrusion increased the internal hydrogen content significantly, and a highly porous structure was seen after WAAM deposition.

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Development of Al-TiC Wire Feedstock for Additive Manufacturing by Metal Screw Extrusion

Cited by 10 publications

References 28 publications

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Review of Aluminum Alloy Development for Wire Arc Additive Manufacturing

Large-scale metal additive manufacturing: a holistic review of the state of the art and challenges

Wire arc additive manufacturing of AA5183 with TiC nanoparticles

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