Development of metal matrix composites by direct energy deposition of ‘satellited’ powders

Farayibi, Peter Kayode; Abioye, T.E.; Kennedy, Andrew R.; Clare, Adam T.

doi:10.1016/j.jmapro.2019.07.029

Cited by 29 publications

(12 citation statements)

References 22 publications

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“…Farayibi et al [ 99 ] developed a new MMC using Ti6Al4V + titanium diboride in the powder form via a satelliting method. The resulted mixture consisted of large Ti6Al4V particles, enclosed within finer needle-shaped TiB structures, presented an improved hardness.…”

Section: Metal Matrix Composites (Mmcs)mentioning

confidence: 99%

Metal Matrix Composites Synthesized by Laser-Melting Deposition: A Review

2020

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Metal matrix composites (MMCs) present extraordinary characteristics, including high wear resistance, excellent operational properties at elevated temperature, and better chemical inertness as compared to traditional alloys. These properties make them prospective candidates in the fields of aerospace, automotive, heavy goods vehicles, electrical, and biomedical industries. MMCs are challenging to process via traditional manufacturing techniques, requiring high cost and energy. The laser-melting deposition (LMD) has recently been used to manufacture MMCs via rapid prototyping, thus, solving these drawbacks. Besides the benefits mentioned above, the issues such as lower ultimate tensile strength, yield strength, weak bonding between matrix and reinforcements, and cracking are still prevalent in parts produced by LMD. In this article, a detailed analysis is made on the MMCs manufactured via LMD. An illustration is presented on the LMD working principle, its classification, and dependent and independent process parameters. Moreover, a brief comparison between the wire and powder-based LMDs has been summarized. Ex- and in-situ MMCs and their preparation techniques are discussed. Besides this, various matrices available for MMCs manufacturing, properties of MMCs after printing, possible complications and future research directions are reviewed and summarized.

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Section: Metal Matrix Composites (Mmcs)mentioning

confidence: 99%

Metal Matrix Composites Synthesized by Laser-Melting Deposition: A Review

2020

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“…Their study successfully illustrated that the meltpool created by a laser during the L-PBF process is turbulent, mixing the liquid multiple times over before solidification can take place 30 . In fact, multiple studies have recently revealed that L-PBF melt pool turbulence can sufficiently disperse satellite ceramic particles into a metal matrix 18,23,24 . Figure 3(a) illustrates how it is believed this turbulent melt pool successfully dispersed the coated oxides into the metallic matrix of the build volume.…”

Section: Production Of Dispersion Strengthened Mpeas Via Additive Manmentioning

confidence: 99%

“…Studies have also shown that powder shape and size distribution contribute significantly to the quality of AM builds 21 . Other methods of incorporating nanoparticles into additive powder lots through chemical reactions or depositions have been explored; though the added complexity and expense of these techniques may limit their commercial viability 15,17,[22][23][24][25][26] .…”

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confidence: 99%

Efficient production of a high-performance dispersion strengthened, multi-principal element alloy

Smith

Thompson²,

Gabb

et al. 2020

Sci Rep

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Additive manufacturing currently facilitates new avenues for materials discovery that have not been fully explored. In this study we reveal how additive manufacturing can be leveraged to produce dispersion strengthened (DS), multi-principal element alloys (MPEA) without the use of traditional mechanical alloying or chemical reactions. This new processing technique employed resonant acoustic mixing to coat an equiatomic NiCoCr powder with nano-scale yttrium oxides. Then, through laser powder bed fusion (L-PBF), the coated powder was successfully consolidated into 99.9% dense parts. Microstructural analysis confirmed the successful incorporation and dispersion of nano-scale oxides throughout the build volume. Furthermore, high temperature mechanical testing of the DS alloys showed significant improvements in strength and ductility over the baseline NiCoCr. As a result, this recently discovered processing route opens a new alloy design and production path that is synergistic between additive manufacturing and dispersion strengthening, possibly enabling a new generation of high-performance alloys. Additive manufacturing (AM) techniques have broadened many aspects of component design, enabled part count reduction, and decreased commissioning time for prospective NASA hardware and industrial applications 1. Currently, the bulk of metallic AM research has been conducted on traditional alloys 2-4. Yet, AM facilitates new avenues for materials discovery that have not been fully explored 5,6. For laser powder bed fusion (L-PBF), the finely focused, laser melting of powder is analogous to welding and is thus problematic for alloys that are difficult to weld. Unfortunately, many of the alloys used for ultra-high temperature applications (>1000 °C) fall within this criterion. Therefore, there currently exists a need for high temperature alloys that can be produced through L-PBF or similar AM processes. One alloy system that has shown promise is the multi-principal element alloy (MPEA) class. The discovery and growth of this interesting new class of alloys, coined "High Entropy alloys", has coincided with the development of AM. High entropy alloy development has led to the identification of a wide range of MPEAs, such as the ternary alloy NiCoCr, which has demonstrated impressive mechanical properties over a wide range of temperatures and stresses 7,8. Recent studies have also presented favorable results from producing the NiCoCr alloy using AM 9. The success of fabricating the "Cantor alloy" (NiCoCrMnFe) and its derivatives through AM may result from the small gap between their solidus and liquidus temperatures 10 , thereby, reducing the risk of heat affected zone (HAZ) cracking and lowering residual stresses 11. Unfortunately, the phase simplicity that enhances the manufacturability of alloys such as NiCoCr will also limit their high temperature mechanical properties. An additional strengthening mechanism must be introduced, such as dispersion strengthening (DS). Dispersion strengthening, primarily through the use of oxides,...

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“…The main limitation of PM techniques is related to the price of raw material powders, which are expensive [125]. However, it should be noticed that the AM techniques, such as laser powder bed fusion (LPBF) and directed energy deposition (DED) processes, that are layer-wise manufacturing processes, are rapidly growing in the fabrication of MMNCs [126,127,128,129].…”

Section: Fabrication Of Mmncs Reinforced By Graphenementioning

confidence: 99%

An Overview of the Recent Developments in Metal Matrix Nanocomposites Reinforced by Graphene

2019

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Two-dimensional graphene plateletes with unique mechanical, electrical and thermo-physical properties could attract more attention for their employed as reinforcements in the production of new metal matrix nanocomposites (MMNCs), due to superior characteristics, such as being lightweight, high strength and high performance. Over the last years, due to the rapid advances of nanotechnology, increasing demand for the development of advanced MMNCs for various applications, such as structural engineering and functional device applications, has been generated. The purpose of this work is to review recent research into the development in the powder-based production, property characterization and application of magnesium, aluminum, copper, nickel, titanium and iron matrix nanocomposites reinforced with graphene. These include a comparison between the properties of graphene and another well-known carbonaceous reinforcement (carbon nanotube), following by powder-based processing strategies of MMNCs above, their mechanical and tribological properties and their electrical and thermal conductivities. The effects of graphene distribution in the metal matrices and the types of interfacial bonding are also discussed. Fundamentals and the structure–property relationship of such novel nanocomposites have also been discussed and reported.

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Development of metal matrix composites by direct energy deposition of ‘satellited’ powders

Cited by 29 publications

References 22 publications

Metal Matrix Composites Synthesized by Laser-Melting Deposition: A Review

Metal Matrix Composites Synthesized by Laser-Melting Deposition: A Review

Efficient production of a high-performance dispersion strengthened, multi-principal element alloy

An Overview of the Recent Developments in Metal Matrix Nanocomposites Reinforced by Graphene

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