Laser Additive Manufacturing with Crack‐sensitive Materials

Brückner, Frank; Finaske, Thomas; Willner, Robin; Seidel, André; Nowotny, Steffen; Leyens, Christoph; Beyer, Eckhard

doi:10.1002/latj.201500015

Cited by 12 publications

(7 citation statements)

References 2 publications

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“…In the process zone, the powder is subsequently pre-heated by a laser and finally absorbed by the laser-induced melt pool. By the relative movement between the substrate and the deposition head, three-dimensional structures can be manufactured [ 13 ]. Furthermore, the blown powder approach enables the simultaneous feeding of different powders into the process zone.…”

Section: Introductionmentioning

confidence: 99%

“…Hence, an in situ alloying and an in situ adaption of alloy compositions can be achieved [ 14 ]. Additionally, the LMD process can be combined with auxiliary energy sources (e.g., inductive heating) for tailoring thermal boundary conditions, such as cooling rates and the overall process temperature [ 13 ].…”

Section: Introductionmentioning

confidence: 99%

“…Thus, LMD combines the advantages of near net shape manufacturing, a high freedom regarding the tailoring of thermal process conditions and the possibility of in situ alloying. Therefore, the processing of advanced materials, which often require elevated process temperatures or adapted cooling rates is very promising and was already investigated by various researches [ 13 , 15 , 16 , 17 , 18 ].…”

Section: Introductionmentioning

confidence: 99%

“…Figure13. EDX data along the weld track showing the high degree of dilution in weld track deposited at 900 • C pre-heating temperature, 800 W laser power and 400 mm/min feeding speed.…”

mentioning

confidence: 99%

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Additive Manufacturing of β-NiAl by Means of Laser Metal Deposition of Pre-Alloyed and Elemental Powders

et al. 2021

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The additive manufacturing (AM) technique, laser metal deposition (LMD), combines the advantages of near net shape manufacturing, tailored thermal process conditions and in situ alloy modification. This makes LMD a promising approach for the processing of advanced materials, such as intermetallics. Additionally, LMD allows the composition of a powder blend to be modified in situ. Hence, alloying and material build-up can be achieved simultaneously. Within this contribution, AM processing of the promising high-temperature material β-NiAl, by means of LMD, with elemental powder blends, as well as with pre-alloyed powders, was presented. The investigations showed that by applying a preheating temperature of 1100 °C, β-NiAl could be processed without cracking. Additionally, by using pre-alloyed, as well as elemental powders, a single phase β-NiAl microstructure can be achieved in multi-layer build-ups. Major differences between the approaches were found within substrate near regions. For in situ alloying of Ni and Al, these regions are characterized by an inhomogeneous elemental distribution in a layerwise manner. However, due to the remelting of preceding layers during deposition, a homogenization can be observed, leading to a single-phase structure. This shows the potential of high temperature preheating and in situ alloying to push the development of new high temperature materials for AM.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

“…Figure13. EDX data along the weld track showing the high degree of dilution in weld track deposited at 900 • C pre-heating temperature, 800 W laser power and 400 mm/min feeding speed.…”

mentioning

confidence: 99%

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Additive Manufacturing of β-NiAl by Means of Laser Metal Deposition of Pre-Alloyed and Elemental Powders

et al. 2021

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“…Crack-free processing of titanium aluminides with DED is possible by preheating the substrate during the process [ 14 , 15 , 16 , 17 , 18 ]. The temperature of the substrate or the already built-up volume required to produce crack-free traces must be in the brittle-ductile transition range (550–800 °C) for Ti-based alloys [ 19 ].…”

Section: Introductionmentioning

confidence: 99%

Direct Energy Deposition of TiAl for Hybrid Manufacturing and Repair of Turbine Blades

et al. 2020

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While repair is mainly used to restore the original part geometry and properties, hybrid manufacturing aims to exploit the benefits of each respective manufacturing process regarding either processing itself or resulting part characteristics. Especially with the current implementation of additive manufacturing in the production of TiAl, turbine blades for both hybrid manufacturing and repair new opportunities are enabled. One main issue is the compatibility of the two or more material types involved, which either differ regarding composition or microstructure or both. In this study, a TNMTM-alloy (Ti-Nb-Mo) was manufactured by different processes (casting, forging, laser additive manufacturing) and identically heat-treated at 1290 °C. Chemical compositions, especially aluminum and oxygen contents, were measured, and the resulting microstructures were analyzed with Scanning Electron Microscopy (SEM) and High-energy X-ray diffraction (HEXRD). The properties were determined by hardness measurements and high-temperature compression tests. The comparison led to an overall assessment of the theoretical compatibility. Experiments to combine several processes were performed to evaluate the practical feasibility. Despite obvious differences in the final phase distribution caused by deviations in the chemical composition, the measured properties of the samples did not differ significantly. The feasibility of combining direct energy deposition (DED) with either casting or laser powder bed fusion (LPBF) was demonstrated by the successful build of the dense, crack-free hybrid material.

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Multimaterial Additive Manufacturing of Graded Laves Phase Reinforced NiAlTa Structures by Means of Laser Metal Deposition

Müller¹,

Stellmacher

Riede

et al. 2021

Adv Eng Mater

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Recently, the additive manufacturing (AM) technology laser metal deposition (LMD) has gained a lot of attention for processing crack prone high temperature materials such as nickel‐based superalloys or intermetallics. A feasibility study on LMD of a graded transition from binary ß‐NiAl to Ni50Al42Ta8 is presented with the aim to show the possibility of manufacturing ß‐NiAl‐based structures with a spatially resolved microstructure and subsequently tailored mechanical properties. For achieving this, the alloys Ni50Al50 and Ni50Al42Ta8 are coinjected into the process zone and the powder feeding rates are adapted in a layerwise manner. Due to preheating temperatures of up to 1000 °C, the transition can be manufactured with high relative density and a low degree of cold cracking. Scanning electron microscopy of the transition zone shows the formation of a fine dendritic microstructure consisting of ß‐NiAl dendritic and NiAlTa interdendritic regions. Large area energy‐dispersive X‐ray analysis reveals a gradient in NiAlTa Laves phase content with increasing build height. The observed volume fraction of Laves phase corresponds well to reported values from cast ingots. Finally, hardness measurements along the build‐up direction show an increase in hardness from 300 HV0.1 to 680 HV0.1 indicating a tremendous increase in tensile strength.

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Laser Additive Manufacturing with Crack‐sensitive Materials

Cited by 12 publications

References 2 publications

Additive Manufacturing of β-NiAl by Means of Laser Metal Deposition of Pre-Alloyed and Elemental Powders

Additive Manufacturing of β-NiAl by Means of Laser Metal Deposition of Pre-Alloyed and Elemental Powders

Direct Energy Deposition of TiAl for Hybrid Manufacturing and Repair of Turbine Blades

Multimaterial Additive Manufacturing of Graded Laves Phase Reinforced NiAlTa Structures by Means of Laser Metal Deposition

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