Experimental studies on fabricating functionally gradient material of stainless steel 316L-Inconel 718 through hybrid manufacturing: directed energy deposition and machining

Zhang, Runyu; Nagaraja, Kishore Mysore; Bian, Ning; Fisher, Ethan L.; Ahmadyar, Samir; Bayazitoglu, Kaya; Lu, Hongbing; Li, Wei

doi:10.1007/s00170-022-09304-y

Cited by 11 publications

(3 citation statements)

References 32 publications

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“…[27] One of the examples include the manufacturing of Inconel 718/SS 316 L FGM with DED technique and then utilizing a tungsten carbide milling cutter to improve the surface roughness and dimensional accuracy of the sample. [28,29] Another example is the fabrication of a functionally graded Al x CoCrFeNi high-entropy alloy with variant aluminum concentration using a hybrid powder-bed wire-based DED process. [30] Besides, Dezaki et al [27] provided a comprehensive review discussing the advantages, challenges, and applications of DED and ASHM procedures.…”

Section: Directed Energy Depositionmentioning

confidence: 99%

“…Lattice-structured materials are employed in a wide variety of engineering applications, such as marine applications, [28][29][30]32,33] automotive applications, [34][35][36][37]39] vibration isolation systems, [40][41][42][43] biomedical implants, [44,45,[47][48][49][50] and dental applications. [51][52][53][54] In this section, an overview of their application in different fields will be discussed.…”

Section: Applicationsmentioning

confidence: 99%

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Recent Advancements in Design Optimization of Lattice‐Structured Materials

et al. 2023

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Metamaterials, also known as lattice‐structured materials, imitate the multifunctionality of natural architects as tailoring their physical properties is associated with manipulating their microstructure. As the recent evolution of additive manufacturing enables the creation of intricate geometries with minimal material wastage, improving the design to manufacturing cycle of lattice structured materials has become one of the trending research areas. Triply periodic minimal surface (TPMS) and plate lattice materials are renowned for their exceptional mechanical behavior in lightweight applications. Apparently, several types of design optimization strategies are explored to maximize their performance for better biocompatibility and mechanical loading resistance. Some of these strategies include functional gradation and multimorphology hybridization that are comprehensively described in this review. Their benefits and drawbacks are highlighted with a focus on TPMS and plate lattice materials. The review anticipates the utilization of automated design exploration methods (i.e., topology optimization and data‐driven methods) to further enhance the design optimization procedure of lattice structured materials.

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Section: Directed Energy Depositionmentioning

confidence: 99%

Section: Applicationsmentioning

confidence: 99%

Recent Advancements in Design Optimization of Lattice‐Structured Materials

et al. 2023

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“…The machinability of DED IN718 parts improves with high-temperature machining (400 • C) of the fabricated parts, leading to higher surface quality and significantly lower tool wear than room-temperature machining [17]. The machining aspects of IN718/SS316L functionally graded material (FGM) fabricated by laser DED AM were recently evaluated by Li et al [18] and Zhang et al [19]. In both studies, the machining of the sections in the FGM containing more IN718 than SS316L led to higher cutting forces and the generation of more cutting heat, owing to the higher hardness and strength of the IN718.…”

Section: Introductionmentioning

confidence: 99%

Dry and Minimum Quantity Lubrication Machining of Additively Manufactured IN718 Produced via Laser Metal Deposition

Ozaner,

Kapil,

Sato

et al. 2023

Lubricants

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Inconel 718 (IN718), a Ni-based superalloy, is immensely popular in the aerospace, nuclear, and chemical industries. In these industrial fields, IN718 parts fabricated using conventional and additive manufacturing routes require subsequent machining to meet the dimensional accuracy and surface quality requirements of practical applications. The machining of IN718 has been a prominent research topic for conventionally cast, wrought, and forged parts. However, very little attention has been given to the machinability of IN718 additively manufactured using laser metal deposition (LMD). This lack of research can lead to numerous issues derived from the assumption that the machining behavior corresponds to conventionally fabricated parts. To address this, our study comprehensively assesses the machinability of LMDed IN718 in dry and minimum quantity lubrication (MQL) cutting environments. Our main goal is to understand how LMD process variables and the cutting environment affect cutting forces, tool wear, surface quality, and energy consumption when working with LMDed IN718 walls. To achieve this, we deposited IN718 on SS309L substrates while varying the following LMD process parameters: laser power, powder feed rate, and scanning speed. The results unveil that machining the deposited wall closer to the substrate is significantly more difficult than away from the substrate, owing to the variance in hardness along the build direction. MQL greatly improves machining across all processing parameters regardless of the machining location along the build direction. Laser power is identified as the most influential parameter, along with the recommendation for a specific combination of power feed rate and scanning speed, providing practical guidelines for optimizing the machining process. While MQL positively impacts machinability, hourly energy consumption remains comparable to dry cutting. This work offers practical guidance for improving the machinability of LMDed IN718 walls and the successful adoption of LMD and the additive–subtractive machining chain. The outcomes of this work provide a significant and critical understanding of location-dependent machinability that can help develop targeted approaches to overcome machining difficulties associated with specific areas of the LMDed structure. The finding that MQL significantly improves machining across all processing parameters, particularly in the challenging bottom region, offers practical guidance for selecting optimal cutting conditions. The potential economic benefits of MQL in terms of tool longevity without a substantial increase in energy costs is also highlighted, which has implications for incorporating MQL in several advanced manufacturing processes.

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