Microstructure formation and mechanical properties of ODS steels built by laser additive manufacturing of nanoparticle coated iron-chromium powders

Doñate‐Buendía, Carlos; Kürnsteiner, Philipp; Stern, Felix; Wilms, Markus Benjamin; Streubel, René; Kusoglu, İhsan Murat; Tenkamp, Jochen; Bruder, Enrico; Pirch, Norbert; Barcikowski, Stephan; Durst, Karsten; Schleifenbaum, Johannes Henrich; Walther, Frank; Gault, Baptiste; Gökce, Bilal

doi:10.1016/j.actamat.2020.116566

Cited by 80 publications

(62 citation statements)

References 74 publications

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“…Simulation results are presented here for a single scan LPBF nanoparticle-decorated PM2000 alloy in an argon atmosphere. The composition of the PM2000 adopted in this work (presented in Table 1 following our former experimental investigations [12,23]) presents a ferritic structure in the high-temperature range (from 1000 K to the melting temperature) without solid-state phase transition, according to the Fe-Cr-Al ternary phase diagram reported in Ref. [75].…”

Section: Resultsmentioning

confidence: 92%

“…However, this expensive and complex fabrication route often leads to a low fracture toughness in the fabricated part and is inflexible in the part design [11]. As an alternative, additive manufacturing techniques are capable of producing ODS materials offering high solidification rates in combination with strong Marangoni forces within the melt pool, potentially leading to a homogeneous distribution of the introduced nanoparticles [12]. The distribution of these nanoparticles is highly influenced by the additive manufacturing technique employed and the parameters selected for processing due to differences in the melt pool dynamics.…”

Section: Introductionmentioning

confidence: 99%

“…To address this drawback, alternative supporting procedures have been proposed [20] such as resonant acoustic mixing [21], solid-liquid reaction [22], or colloidal dielectrophoretic deposition [23,24]. Once the nanoparticle-additivated powder is obtained, the processing technique employed to generate the ODS steel samples and the experimental parameters selected determine the evolution of the nanoparticles, their final size, and dispersion in the ODS steel [12,25]. Even techniques with a similar working principle to LPBF like direct energy deposition (DED)-both laser additive manufacturing techniques-lead to differences in the nanoparticle agglomeration during processing due to the higher cooling rates of the melt pool achieved in LPBF that favor the preservation of the nanoparticle dispersion [12].…”

Section: Introductionmentioning

confidence: 99%

“…Once the nanoparticle-additivated powder is obtained, the processing technique employed to generate the ODS steel samples and the experimental parameters selected determine the evolution of the nanoparticles, their final size, and dispersion in the ODS steel [12,25]. Even techniques with a similar working principle to LPBF like direct energy deposition (DED)-both laser additive manufacturing techniques-lead to differences in the nanoparticle agglomeration during processing due to the higher cooling rates of the melt pool achieved in LPBF that favor the preservation of the nanoparticle dispersion [12]. Even though these experimental observations provide an insight into the nanoparticle behaviors, further investigations would be required to completely understand the undergoing nanoparticle capture (nanoparticles trapped interior the microstructure), enrichment (local concentration increase of nanoparticles), and agglomeration processes [26][27][28][29].…”

Section: Introductionmentioning

confidence: 99%

“…This proposed scheme is aimed to demonstrate the chronological and spatial variation of multiple traced nanoparticles with respect to various factors (such as chemical composition and size distribution), which enables graphical and statistical analysis on the nanoparticle migration and further effects, such as nanoparticle capture, enrichment, and agglomeration. The nanoparticle compositions used in the simulation are chosen based on our experimental studies on the additive manufacturing of ODS steels, including the use of Y 2 O 3 [12,23] and YIG (yttrium iron garnet, Y 3 Fe 5 O 12 ) [23] nanoparticles. Influences from different types of nanoparticle size distribution, including the monomodal, normal, and log-normal distributions fitted from the experimental measurement [23], are also investigated and discussed in this work.…”

Section: Introductionmentioning

confidence: 99%

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Nanoparticle Tracing during Laser Powder Bed Fusion of Oxide Dispersion Strengthened Steels

et al. 2021

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The control of nanoparticle agglomeration during the fabrication of oxide dispersion strengthened steels is a key factor in maximizing their mechanical and high temperature reinforcement properties. However, the characterization of the nanoparticle evolution during processing represents a challenge due to the lack of experimental methodologies that allow in situ evaluation during laser powder bed fusion (LPBF) of nanoparticle-additivated steel powders. To address this problem, a simulation scheme is proposed to trace the drift and the interactions of the nanoparticles in the melt pool by joint heat-melt-microstructure–coupled phase-field simulation with nanoparticle kinematics. Van der Waals attraction and electrostatic repulsion with screened-Coulomb potential are explicitly employed to model the interactions with assumptions made based on reported experimental evidence. Numerical simulations have been conducted for LPBF of oxide nanoparticle-additivated PM2000 powder considering various factors, including the nanoparticle composition and size distribution. The obtained results provide a statistical and graphical demonstration of the temporal and spatial variations of the traced nanoparticles, showing ∼55% of the nanoparticles within the generated grains, and a smaller fraction of ∼30% in the pores, ∼13% on the surface, and ∼2% on the grain boundaries. To prove the methodology and compare it with experimental observations, the simulations are performed for LPBF of a 0.005 wt % yttrium oxide nanoparticle-additivated PM2000 powder and the final degree of nanoparticle agglomeration and distribution are analyzed with respect to a series of geometric and material parameters.

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Section: Resultsmentioning

confidence: 92%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Nanoparticle Tracing during Laser Powder Bed Fusion of Oxide Dispersion Strengthened Steels

et al. 2021

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Influence of Colloidal Additivation with Surfactant‐Free Laser‐Generated Metal Nanoparticles on the Microstructure of Suction‐Cast Nd–Fe–B Alloy

Liu,

Yang,

Staab

et al. 2023

Adv Eng Mater

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Development of new powder feedstocks using nanoparticles (NPs) has the potential to influence the microstructure of as‐built parts and overcome the limitations of current powder‐based additive manufacturing (AM) techniques. The focus of this study is to investigate the impact of NP‐modified magnetic microparticle powder feedstock on the microstructure of suction‐cast Nd‐Fe‐B‐based alloys. This particular casting method has been recognized for its ability to replicate, to some extent, the melting and rapid solidification stages inherent to metal powder‐based AM techniques such as Powder Bed Fusion using a Laser Beam (PBF‐LB). Two types of NP materials, Ag and ZrB2, are used, and their effects on the grain size distribution and dendritic structures are evaluated after suction casting. Ag NPs result in smaller, more uniform grain sizes. ZrB2 NPs result in uniformly distributed grain sizes at much lower mass loadings. The results show that feedstock powder surface modification with low‐melting‐point metal NPs can improve permanent magnets’ microstructure and magnetic properties, at below 1 vol.%, equal to sub‐monolayer surface loads. This study highlights the potential of using NPs to develop new powder feedstocks for AM, significantly improving the final part’s properties.This article is protected by copyright. All rights reserved.

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Unique Yttria Nanoparticle Strengthening in an Inconel 718 Superalloy Fabricated by Additive Manufacturing

Dai,

Zhu,

Yan

et al. 2023

Adv Materials Technologies

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Oxide dispersion strengthened (ODS) nickel (Ni)‐based superalloys are advanced materials known for their outstanding tensile and creep performance at temperatures exceeding 1000 °C. Nevertheless, their conventional synthesis presents a longstanding challenge in cost‐effectively producing intricate components for critical applications. In this work, electrostatic self‐assembly (ESA) of powders with the laser powder bed fusion (LPBF) process have been successfully combined to produce yttria ODS Inconel 718 (IN718) alloy for the first time. The approach has demonstrated a significant contribution of yttria to the strength of IN718 after the solid solution heat treatment, as evidenced by ≈50% improvement in room temperature yield strength with a 0.5 wt.% yttria addition. The addition of yttria by this process leads to a heterogeneous microstructure. This heterogeneous microstructure comprises two distinct grain areas with varying amounts of yttria nanoparticles and dislocation storage. It has been shown that the yield strength increase can be predicted by the combination of both Y2O3 dispersion strengthening and dislocation strengthening mechanisms. These findings offer an effective approach to tailor heterogeneous microstructures, unlocking new opportunities for cost‐effectively producing high‐performance ODS Ni‐based superalloy products with excellent mechanical properties.

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Microstructure formation and mechanical properties of ODS steels built by laser additive manufacturing of nanoparticle coated iron-chromium powders

Cited by 80 publications

References 74 publications

Nanoparticle Tracing during Laser Powder Bed Fusion of Oxide Dispersion Strengthened Steels

Nanoparticle Tracing during Laser Powder Bed Fusion of Oxide Dispersion Strengthened Steels

Influence of Colloidal Additivation with Surfactant‐Free Laser‐Generated Metal Nanoparticles on the Microstructure of Suction‐Cast Nd–Fe–B Alloy

Unique Yttria Nanoparticle Strengthening in an Inconel 718 Superalloy Fabricated by Additive Manufacturing

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