Evaluation of the mechanical properties of Inconel 718 components built by laser cladding

Tabernero, I.; Lamíkiz, Aitzol; Martı́nez, Silvia; Ukar, Eneko; Figueras, J.

doi:10.1016/j.ijmachtools.2011.02.003

Cited by 150 publications

(48 citation statements)

References 15 publications

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“…LMD can be used to process IN718, for example to repair or to additive manufacture components in turbo engines, which brings high economic benefits. Thus, investigations on LMD for IN718 have been attracted more and more attention [22][23][24][25]. One research focus is to develop high-deposition-rate laser metal deposition (HDR-LMD) for IN718 [26][27][28][29] in order to improve productivity.…”

Section: Introductionmentioning

confidence: 99%

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Chen

Pirch

Gasser

et al. 2017

Metals

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Abstract:For the purpose of improving the productivity of laser metal deposition (LMD), the focus of current research is set on increasing the deposition rate, in order to develop high-deposition-rate LMD (HDR-LMD). The presented work studies the effects of the powder stream on HDR-LMD with Inconel 718. Experiments have been designed and conducted by using different powder feeding nozzles-a three-jet and a coaxial powder feeding nozzle-since the powder stream is mainly determined by the geometry of the powder feeding nozzle. After the deposition trials, metallographic analysis of the samples has been performed. The laser intensity distribution (LID) and the powder stream intensity distribution (PID) have been characterized, based on which the processes have been simulated. Finally, for verifying and correcting the used models for the simulation, the simulated results have been compared with the experimental results. Through the conducted work, suitable boundary conditions for simulating the process with different powder streams has been determined, and the effects of the powder stream on the process have also been determined. For a LMD process with a three-jet nozzle a substantial part of the powder particles that hit the melt pool surface are rebounded; for a LMD process with a coaxial nozzle almost all the particles are caught in the melt pool. This is due to the different particle velocities achieved with the two different nozzles. Moreover, the powder stream affects the heat exchange between the heated particles and the melt pool: a surface boundary condition applies for a powder stream with lower particle velocities, in the experiment provided by a three-jet nozzle, and a volumetric boundary condition applies for a powder stream with higher particle velocities, provided by a coaxial nozzle.

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Section: Introductionmentioning

confidence: 99%

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Chen

Pirch

Gasser

et al. 2017

Metals

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“…These elements include: aluminum, boron, carbon, chromium, cobalt, hafnium, iron, magnesium, manganese, molybdenum, niobium, rhenium, tantalum, titanium, tungsten, and zirconium [15]. A broad range of superalloys has been evaluated for LMD including Alloy-625 [13,[16][17][18][19][20], Alloy-718 [6,[21][22][23][24][25][26][27][28][29][30][31], Alloy-738 [12,32], CMSX4 [33][34][35], Rene41 [36,37] and Waspaloy [10,38]. There are some parameters of particular importance to LMD, as listed in Table 1, to have a controlled deposition.…”

Section: Materials Characteristics and Process Parametersmentioning

confidence: 99%

Review of Laser Deposited Superalloys Using Powder as an Additive

Segerstark¹,

Andersson²,

Svensson³

2014

8th International Symposium on Superalloy 718 and Derivatives (2014)

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In this paper laser metal deposition (LMD) with blown powder was reviewed with respect to the material behavior of nickel and nickel-iron based superalloys. The key benefits of LMD are claimed to be increased design freedom of components as well as reduced environmental impact since it enables near net shape manufacturing. This review considers the LMD processing parameters such as laser power, powder feed rate, spot size, standoff distance, and traverse speed, together with aspects related to the powder e.g. morphology, porosity, inclusion and satellite content. Special emphasis was put on how these parameters affect the deposit and substrate in terms of cracking, porosity, inclusions, phase transformations, and other material related phenomena. A characteristic microstructure of LMD deposited superalloys has a columnar dendrite growth in the vertical build up direction. The grain growth can however be manipulated, making it more equiaxed by, for instance, altering process parameters and/or scanning path. Residual stresses in LMD samples are unevenly distributed and large residual tensile stresses can be found at the surface of the deposit while large compressive stresses are located close to the substrate in the core of the deposit. One of the most important parameter is considered to be the specific energy input which largely influences the m elt pool during deposition which in turn can be related to the microstructure, residual stress and, process related defects such as porosity, cracking, lack of fusion and, dilution.

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“…He stated that the machinability of aerospace materials should be considered in much broader terms than machining tests that are directed at the tool performance/ material removal rates. A group of researchers carried out mechanical [15] and machinability [14] assessment of a nickel-based superalloy (Inconel 718) in machining operations. Shokrani et al [16] have reviewed and identified difficult-to-machine materials such as alloys used in the aerospace, nuclear and medical industries.…”

Section: Introductionmentioning

confidence: 99%

Prediction of Cutting Forces in Ball-End Milling of Multi-Layered Metal Materials

Župerl

Čuš

Irgolič

2016

SV-JME

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340 INTRODUCTIONEnd milling of multi-layered metal materials is an important manufacturing function in the automotive tool making industry. The most well-known process to fabricate the multi-layered materials was developed by Sandia National Laboratories and is known as laser engineered net shaping (LENS). The company Optomec makes and sells equipment based on Sandia's LENS process. LENS uses a laser power of up to 4 kW to fuse metal powders into threedimensional structures layer by layer, guided by a CAD model. The process is enclosed in an airtight, argon environment which prevents oxidation. The closed-loop process controls ensure the geometric and mechanical integrity of the completed part [1]. Due to the inhomogeneous structure of multi-layered metal materials manufactured with the LENS process, the machining of these materials leads to undesirable effects such as tool breakage, rapid cutting tool wear, surface deterioration and shelling of the cladded layers (delayerization). All of these undesirable effects are directly connected to the cutting tool forces acting on the workpiece. Delayerization of material is tightly related to the cutting force normal to the layer deposition plane [2]. Cutting forces can be seen as a control parameter for many other phenomena involved in the milling of these materials. Therefore, there is a considerable practical interest to analyse and predict precisely the cutting forces during milling of multilayered metal materials. Knowing the cutting forces is fundamental for understanding the cutting processes, optimizing the milling operations and evaluating the presence of instabilities that could affect the effectiveness of milling processes.Many cutting force models have been developed for ball-end milling processes, especially the mechanistic models, including the work of Sui [3], Zhou [4] and Milfelner [5]. Mechanistic models try to relate the cutting forces to the chip geometry by experimentally determined cutting force coefficients. The major problem is the lack of cutting force coefficients for oblique cutting and for different tool/workpiece combinations, such as multi-layered laser based metal deposition (LBMD) materials. The coefficients are obtained by labour intensive and timeconsuming cutting experiments and adjusting of model parameters. The problem is even more complicated due to the highly nonlinear and inhomogeneous nature of multi-layer LBMD materials as compared with metals. For these reasons, the generation of specific cutting energy data for LBMD materials is more challenging. No evidence of research efforts that attempts to model the cutting forces in milling LBMD materials has been found. Additionally, the obtained models are also difficult to extend to different tooling systems, conditions, and parameters.An artificial neural network (ANN) can be used as an alternative to analytical approaches. The method has become widespread in the predictive modelling of milling processes [6] to [8]. ANNs determine an implicit relationship between the input(s) and out...

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Evaluation of the mechanical properties of Inconel 718 components built by laser cladding

Cited by 150 publications

References 15 publications

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

The Influence of the Powder Stream on High-Deposition-Rate Laser Metal Deposition with Inconel 718

Review of Laser Deposited Superalloys Using Powder as an Additive

Prediction of Cutting Forces in Ball-End Milling of Multi-Layered Metal Materials

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