Enhancing mechanical properties of wire + arc additively manufactured INCONEL 718 superalloy through in-process thermomechanical processing

Xu, Xin; Ganguly, Saibal; Ding, Jialuo; Seow, Cui Er; Williams, Stewart

doi:10.1016/j.matdes.2018.10.038

Cited by 126 publications

(48 citation statements)

References 27 publications

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“…Plasma arc-based WAAM was used to investigate the properties and microstructure of Inconel 718 superalloy in three conditions: as-built, with interpass rolling, and rolled with heat treatment in agreement with AMS-5662M [63]. The as-built samples exhibited the typical dendritic structure with Laves phase aligned with the build direction.…”

Section: Methodsmentioning

confidence: 99%

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Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

et al. 2019

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Additive manufacturing has revolutionized the manufacturing paradigm in recent years due to the possibility of creating complex shaped three-dimensional parts which can be difficult or impossible to obtain by conventional manufacturing processes. Among the different additive manufacturing techniques, wire and arc additive manufacturing (WAAM) is suitable to produce large metallic parts owing to the high deposition rates achieved, which are significantly larger than powder-bed techniques, for example. The interest in WAAM is steadily increasing, and consequently, significant research efforts are underway. This review paper aims to provide an overview of the most significant achievements in WAAM, highlighting process developments and variants to control the microstructure, mechanical properties, and defect generation in the as-built parts; the most relevant engineering materials used; the main deposition strategies adopted to minimize residual stresses and the effect of post-processing heat treatments to improve the mechanical properties of the parts. An important aspect that still hinders this technology is certification and nondestructive testing of the parts, and this is discussed. Finally, a general perspective of future advancements is presented.

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Section: Methodsmentioning

confidence: 99%

“…Precipitates found under SEM of the rolled with heat treatment sample (green: residual Laves phase, yellow: δ phase, purple: nanoscale precipitates along grain boundaries) (adapted from [63]).…”

Section: Figurementioning

confidence: 99%

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

et al. 2019

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“…The required penetration depth for the plastic strain can be reduced by reducing the re-melting depth or the layer height, the latter being undesirable due to a possible reduction in deposition rate. Certain power sources, such as plasma transferred arc or tungsten inert gas, for example, Ref 45,46,47 can have less re-melting (compared to gas metal arc power sources) at similar deposition rates, making them more compatible for inter-pass rolling of single passes ( Ref 44,46,48). Other DED systems with lower layer height and less re-melting, such as laser + powder or laser + wire deposition ( Ref 43,42,49), might also be very suitable for inter-pass rolling.…”

Section: The Effect Of Rolling On the Plastic Strain Distributionmentioning

confidence: 99%

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

Abbaszadeh

Hönnige

Martina

et al. 2019

J. of Materi Eng and Perform

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Cold rolling can be used in-process or post-process to improve microstructure, mechanical properties and residual stress in directed-energy-deposition techniques, such as the high deposition rate wire + arc additive manufacturing (WAAM) process. Finite element simulations of the rolling process are employed to investigate the effect of rolling parameters, in particular rolling load and roller profile radius on the residual stress field as well as plastic strain distribution for the profiled roller. The results show the response to rolling of commonly used structural metals in WAAM, i.e., AA2319, S335JR steel and Ti-6Al-4V, taking into account the presence of residual stresses. The rolling load leads to changes in the location and the maximum value of the compressive residual stresses, as well as the depth of the compressive residual stresses. However, the roller profile radius only changes the maximum value of these compressive residual stresses. Changing the rolling load influences the equivalent plastic strain close to the top surface of the wall as well as in deeper areas, whereas the influence of the roller profile radius is negligible. The plastic strain distribution is virtually unaffected by the initial residual stresses prior to rolling. Finally, design curves were generated from the simulations for different materials, suggesting ideal rolling load and roller profile combinations for microstructural improvement requiring certain plastic strains at a specific depth of the additive structure.

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“…Yangfan et al [17] used the different heat input to increase the welding cooling time in the TIG process to reduce the hot cracking. The casting process of In718 [18] shows that the Laves phase significantly decreases by increasing the cooling rate. For example, no Laves phase was found in the alloys solidified at a very high cooling rate in the levitation experiment [19].…”

Section: Introductionmentioning

confidence: 99%

Influence of Heat Input on the Formation of Laves Phases and Hot Cracking in Plasma Arc Welding (PAW) Additive Manufacturing of Inconel 718

Artaza

Bhujangrao

Suárez

et al. 2020

Metals

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Nickel-based alloys have had extensive immersion in the manufacturing world in recent decades, especially in high added value sectors such as the aeronautical sector. Inconel 718 is the most widespread in terms of implantation. Therefore, the interest in adapting the manufacture of this material to additive manufacturing technologies is a significant objective within the scientific community. Among these technologies for the manufacture of parts by material deposition, plasma arc welding (PAW) has advantages derived from its simplicity for automation and integration on the work floor with high deposition ratios. These characteristics make it very economically appetizing. However, given the tendency of this material to form precipitates in its microstructure, its manufacturing by additive methods is very challenging. In this article, three deposition conditions are analyzed in which the energy and deposition ratio used are varied, and two cooling strategies are studied. The interpass cooling strategy (ICS) in which a fixed time is expected between passes and controlled overlay strategy (COS) in which the temperature at which the next welding pass starts is controlled. This COS strategy turns out to be advantageous from the point of view of the manufacturing time, but the deposition conditions must be correctly defined to avoid the formation of Laves phases and hot cracking in the final workpiece.

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Enhancing mechanical properties of wire + arc additively manufactured INCONEL 718 superalloy through in-process thermomechanical processing

Cited by 126 publications

References 27 publications

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

Influence of Heat Input on the Formation of Laves Phases and Hot Cracking in Plasma Arc Welding (PAW) Additive Manufacturing of Inconel 718

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Enhancing mechanical properties of wire + arc additively manufactured INCONEL 718 superalloy through in-process thermomechanical processing

Cited by 126 publications

References 27 publications

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

Influence of Heat Input on the Formation of Laves Phases and Hot Cracking in Plasma Arc Welding (PAW) Additive Manufacturing of Inconel 718

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Enhancing mechanical properties of wire + arc additively manufactured INCONEL 718 superalloy through in-process thermomechanical processing