Oxide accumulation effects on wire + arc layer-by-layer additive manufacture process

Xu, Xin; Ding, Jialuo; Ganguly, Saibal; Diao, Chenglei; Williams, Stewart

doi:10.1016/j.jmatprotec.2017.10.030

Cited by 89 publications

(44 citation statements)

References 19 publications

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“…Furthermore, unmelted particles or lack of fusion defects (micrometre scale) often result in components that are not fully-dense (relative density ranging from 90.9% to 99.9% [11]). In an earlier study the authors used Wire plus Arc Additive Manufacture (WAAM) [4], a DED AM process using wire as the feedstock and an arc as the heat source, to deposit fully-dense maraging steel components [6,16]. The resulting microstructure featured severe elemental segregations and a large proportion of columnar grains.…”

Section: Introductionmentioning

confidence: 99%

Improving mechanical properties of wire plus arc additively manufactured maraging steel through plastic deformation enhanced aging response

Ganguly

Ding

et al. 2019

Materials Science and Engineering: A

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Maraging steel gains ultrahigh strength through aging; however, wire plus arc additively manufactured maraging steel features a columnar-dendritic structure with associated segregation and shows a much less pronounced aging response. In this paper, plastic deformation was introduced through interpass cold rolling during the layer-by-layer deposition process. After aging, the ultimate tensile strength (UTS) was improved substantially from 1410MPa (unrolled) to 1750MPa (50kN rolled). Rolling induced partial recrystallization to break the dendritic structure and form high-angle grain boundaries, which promoted the atoms diffusion to enable a more uniform solutionizing process and improved the subsequent aging response by 105-110%. The main contribution of overall strengthening of the rolled alloy was attributed to the effective aging process, accounting for more than 95% of the entire strength increase.

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Section: Introductionmentioning

confidence: 99%

Improving mechanical properties of wire plus arc additively manufactured maraging steel through plastic deformation enhanced aging response

Ganguly

Ding

et al. 2019

Materials Science and Engineering: A

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“…This stands in contrast to studies on other additive manufacturing processes (such as laser powder bed fusion (LPBF) and direct energy deposition (DED)), where free oxygen in the process atmosphere is often reported to be the critical factor for oxide formation. [15,17] In Thijs et al, [17] for example, the formation of Al-and Ti-rich oxide inclusions during LPBF processing of a maraging steel was explained to occur due to oxygen from the process atmosphere, which dissolves in the melt where it reacts with Ti and Al in the steel. According to Ding et al, [15] similar events take place during wire arc DED of a similar material.…”

Section: Discussionmentioning

confidence: 99%

“…It is in this sense a potential candidate for production of high-performance components. However, it has been reported that oxide inclusions may occur in components fabricated by both laser [15][16][17] and electron beam [18] additive manufacturing. Their presence may inhibit proper wetting in-between successive layers and act as fatigue crack nucleation sites.…”

Section: Introductionmentioning

confidence: 99%

Effect of Powder Recycling on Defect Formation in Electron Beam Melted Alloy 718

Gruber

Luchian

Hryha

et al. 2020

Metall Mater Trans A

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The extent to which powder recycling can be permitted before risking a loss in performance of critical components is a major aspect for the viability of electron beam melting (EBM). In this study, the influence of powder oxidation during multi-cycle EBM processing on the formation of oxide-related defects in Alloy 718 is investigated. The amount of defects and their distribution in samples produced from virgin and re-used powder is studied by means of image analysis and oxygen measurements. Morphological analysis using scanning electron microscopy is performed to understand their origin and formation mechanism. The results indicate a clear correlation between the powder oxygen content and the amount of oxide inclusions present in the investigated samples. The inclusions consist of both molten and unmolten Al-rich oxide which originates from the surface of the recycled powder. Upon interaction with the electron beam, the oxide tends to cluster in the liquid metal and form critical sized defects. Hot isostatic pressing can be successfully used to densify samples produced from virgin powder. However, in the material fabricated from recycled powder, a considerable amount of damage relevant oxide inclusion defects remain after HIP treatment, especially in the contour region. It is suggested that the quality of EBM-processed Alloy 718 is at present dependent on the oxygen level in the powder in general, and on the surface chemistry of the power in particular, which needs to be controlled to maintain a low amount of inclusions.

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“…e disadvantage of WAAM technology is that its manufacturing accuracy is not as good as that of laser additive manufacturing and electron beam additive manufacturing [16][17][18][19][20]. In recent years, WAAM technology has attracted considerable attention in the aerospace industry, mechanical equipment industry, and other fields [21][22][23][24][25].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Properties of a 2.25Cr1Mo0.25V Heat‐Resistant Steel Produced by Wire Arc Additive Manufacturing

Guo

Liu

et al. 2020

Advances in Materials Science and Engineering

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Wire arc additive manufacturing (WAAM) technology was used to produce samples of a 2.25Cr1Mo0.25V heat-resistant steel. The phase composition, microstructure, and crystal structure of the investigated material in the as-cladded state and postcladding heat-treated (705°C × 1 h) state were analysed by optical emission spectrometry (OES), optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The properties of the investigated material in the as-cladded state and postcladding heat-treated (705°C × 1 h) state were determined by a microhardness tester, mechanical properties tester, and Charpy impact tester. Through a study of the microstructure and properties, it is found that the investigated material produced by WAAM exhibits good forming quality and excellent metallurgical bonding properties, and no obvious defects are found. The microstructure consists mainly of Bg (granular bainite) and troostite precipitated at the grain boundaries. The results from high-resolution transmission electron microscopy observations show that the crystal structures of the 2.25Cr1Mo0.25V heat-resistant steel samples produced by WAAM in the as-cladded condition have many defects, such as dislocations and martensite-austenite (M-A) constituents, and their grain edges are sharp. There is a dramatic decrease in the dislocations in the 2.25Cr1Mo0.25V heat-resistant steel samples produced by the WAAM condition after the postcladding heat treatment (705°C × 1 h), and the grains become smooth. The distribution of the microhardness in the longitudinal and transverse cross sections of the samples is very uniform. The average longitudinal and transverse microhardness of the samples in the as-cladded state is 310 HV0.5 and 324 HV0.5, respectively. The average longitudinal and transverse microhardness of the samples after post-cladding heat treatment is 227 HV0.5 and 229 HV0.5, respectively. The yield strength of the samples without a postcladding heat treatment is 743 MPa, the tensile strength is 951 MPa, the elongation is 10%, and the Charpy impact value at -20°C is 15 J. After the postcladding heat treatment, the yield strength, tensile strength, elongation, and Charpy impact value of the samples are 611 MPa, 704 MPa, 14.5%, and 70 J, respectively.

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Oxide accumulation effects on wire + arc layer-by-layer additive manufacture process

Cited by 89 publications

References 19 publications

Improving mechanical properties of wire plus arc additively manufactured maraging steel through plastic deformation enhanced aging response

Improving mechanical properties of wire plus arc additively manufactured maraging steel through plastic deformation enhanced aging response

Effect of Powder Recycling on Defect Formation in Electron Beam Melted Alloy 718

Microstructure and Properties of a 2.25Cr1Mo0.25V Heat‐Resistant Steel Produced by Wire Arc Additive Manufacturing

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