Effect of ultrasonic micro-forging treatment on microstructure and mechanical properties of GH3039 superalloy processed by directed energy deposition

Li, Qingqing; Zhang, Yong; Chen, Jie; Guo, Bugao; Wang, Weicheng; Jing, Yuhai; Liu, Yong

doi:10.1016/j.jmst.2020.09.001

Cited by 33 publications

(9 citation statements)

References 61 publications

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“…Ye et al [108] (DED-laser) and Li et al [109] (DEDlaser) developed a hot ultrasonic micro-forging system with an operating frequency of 20 kHz; Xiong et al [110] (DEDarc), a hot hammer penning system with an operating frequency of 21 Hz. These systems [108][109][110] (Fig. 12) resemble the cold hammer previously shown in Fig.…”

Section: Hammering Peening and Forgingmentioning

confidence: 99%

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Farias,

dos Santos,

Oliveira

2024

Int J Adv Manuf Technol

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Directed energy deposition (DED) additive manufacturing systems have been developed and optimized for typical engineering materials and operational requirements. However, parts fabricated via DED often demonstrate a diminished material response, encompassing inferior mechanical properties and heat treatment outcomes compared to traditionally manufactured components (e.g., wrought and cast materials). As a result, parts produced by DED fail to meet stringent specifications and industry requirements, such as those in the nuclear, oil and gas, and aeronautics sectors, potentially limiting the industrial scalability of DED processes. To address these challenges, systems integrating DED with interlayer (cold or hot) mechanical deformation (e.g., rolling and hammering/peening, forging) have been developed. These systems refine the microstructure, mitigate the typical crystallographic texture through static and/or dynamic recrystallization, and enhance mechanical properties and heat treatment responses without altering material specifications. In this regard, the present state-of-the-art review reports the DED + interlayer mechanical deformation systems and their variants, and their potential and limitations, providing a critical analysis to support the development and adaptation of this technology to overcome the process and material limitations that currently prevent the large-scale industrial adoption of DED processes. Furthermore, a detailed description of the grain size refinement mechanisms induced by interlayer mechanical deformation and their respective effects on the mechanical properties of commonly used 3D-printed engineering alloys (e.g., Ti-6Al-4V, Inconel 718, various low-alloy steels, AISI 316L stainless steel, and Al-based series 2xxx) is comprehensively analyzed.

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Section: Hammering Peening and Forgingmentioning

confidence: 99%

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Farias,

dos Santos,

Oliveira

2024

Int J Adv Manuf Technol

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“…The goal is to achieve integration of shape and performance throughout the AM process. The incorporation of ultrasonic peening into the interlayer strengthening of the AM process presents a promising solution for addressing the non-uniform distribution of internal microstructure, encompassing factors such as grain morphology, crystallographic orientation, substructure, and element segregation [117,124,125,140,146,147,[188][189][190][191][192]. This non-uniformity results from varying temperature gradients, cooling rates, and complex thermal cycles during the AM process.…”

Section: Ipd-ihped Ammentioning

confidence: 99%

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Lv,

Liang,

et al. 2024

Int. J. Extrem. Manuf.

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Metal additive manufacturing (AM) technologies have made significant progress in the basic theoretical field since their invention in the 1970s. However, performance instability during continuous processing, such as thermal history, residual stress accumulation, and columnar grain epitaxial growth, consistently hinders their broad application in standardized industrial production. To overcome these challenges, performance-control-oriented hybrid AM (HAM) technologies have been introduced. These technologies, by leveraging external auxiliary processes, aim to regulate microstructural evolution and mechanical properties during metal AM. In this context, HAM technologies for molten pool regulation and solidified material deformation are identified as energy field-assisted AM (EFed AM, e.g., ultrasonic, electromagnetic, heat, etc.) technologies and interlayer plastic deformation-assisted AM (IPDed AM, e.g., laser shock peening, rolling, ultrasonic peening, friction stir process, etc.) technologies, respectively. A detailed and systematic review of performance-control-oriented HAM technologies is then provided. This review covers the influence of external energy fields on the melting, flow, and solidification behavior of materials, and the regulatory effects of interlayer plastic deformation on grain refinement, nucleation, and recrystallization. Furthermore, the role of performance-control-oriented HAM technologies in managing residual stress conversion, metallurgical defect closure, mechanical property improvement, and anisotropy regulation is thoroughly reviewed and discussed. The review concludes with an analysis of future development trends in EFed AM and IPDed AM technologies.

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“…Some early studies have explored the possibility of processing materials using hybrid manufacturing approaches, which concurrently combine additive technologies with tooling to do mechanical work on the build [42]. Some notable examples include in-line rolling [43,44] and forging [45] to refine the microstructure in directed energy deposition (DED) processes, or in-situ laser or shot peening [46,47] to produce compressive stresses and raise the strain energy in materials produced by laser powder bed fusion (LPBF). The first strategy is restricted to AM parts that tolerate low dimensional accuracy, since the repeated deformation may change the build geometry substantially.…”

Section: Revamping Gbe Through Additive Manufacturingmentioning

confidence: 99%

Broadening the design space of engineering materials through “additive grain boundary engineering”

Seita

Gao

2022

J Mater Sci

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Grain boundary engineering (GBE) is one of the most successful processing strategies to improve the properties of polycrystalline solids. However, the extensive thermomechanical processes involved during GBE restrict its use to selected applications and materials. In this viewpoint paper, we discuss the opportunity provided by additive manufacturing (AM) technology to broaden the applicability of the GBE paradigm and, consequently, the design space for engineering materials. By integrating specially-designed thermomechanical processing within AM, it would be possible to produce bulk, near-net-shape parts with complex geometry and GBE microstructure. We discuss the major challenges in this endeavor and propose some possible strategies to achieve this goal, which we refer to as “additive-GBE”.

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Effect of ultrasonic micro-forging treatment on microstructure and mechanical properties of GH3039 superalloy processed by directed energy deposition

Cited by 33 publications

References 61 publications

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Broadening the design space of engineering materials through “additive grain boundary engineering”

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