Robust Metal Additive Manufacturing Process Selection and Development for Aerospace Components

Gradl, Paul R.; Tinker, Darren C.; Park, Alison; Mireles, Omar R.; Garcia, Marissa B.; Wilkerson, Ryan; Mckinney, Christopher

doi:10.1007/s11665-022-06850-0

Cited by 80 publications

(23 citation statements)

References 328 publications

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“…At 1,093 °C and 20 MPa, HIP GRX-810 ruptured after 6,500 h of creep whereas the as-built test was terminated at 1% strain (over 2,800 h). All other non-ODS alloys considered, namely NiCoCr, AM superalloy 718, AM superalloy 625 (at 14MPa) and wrought Haynes 230, ruptured in under 40 h. The orders of magnitude improvement in creep performance by GRX-810 is also shown in Table 1, with time to reach 1% strain at 1,093 °C under 20 MPa of stress for each alloy 5,[47][48][49] .…”

Section: Mechanical Properties Of Grx-810mentioning

confidence: 92%

A 3D printable alloy designed for extreme environments

Smith

Kantzos

Zarkevich

et al. 2023

Nature

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Multiprincipal-element alloys are an enabling class of materials owing to their impressive mechanical and oxidation-resistant properties, especially in extreme environments1,2. Here we develop a new oxide-dispersion-strengthened NiCoCr-based alloy using a model-driven alloy design approach and laser-based additive manufacturing. This oxide-dispersion-strengthened alloy, called GRX-810, uses laser powder bed fusion to disperse nanoscale Y2O3 particles throughout the microstructure without the use of resource-intensive processing steps such as mechanical or in situ alloying3,4. We show the successful incorporation and dispersion of nanoscale oxides throughout the GRX-810 build volume via high-resolution characterization of its microstructure. The mechanical results of GRX-810 show a twofold improvement in strength, over 1,000-fold better creep performance and twofold improvement in oxidation resistance compared with the traditional polycrystalline wrought Ni-based alloys used extensively in additive manufacturing at 1,093 °C5,6. The success of this alloy highlights how model-driven alloy designs can provide superior compositions using far fewer resources compared with the ‘trial-and-error’ methods of the past. These results showcase how future alloy development that leverages dispersion strengthening combined with additive manufacturing processing can accelerate the discovery of revolutionary materials.

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Section: Mechanical Properties Of Grx-810mentioning

confidence: 92%

A 3D printable alloy designed for extreme environments

Smith

Kantzos

Zarkevich

et al. 2023

Nature

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“…However, a team of researchers worked on selection methodology while considering geometry, metallurgical characteristics, cost, postprocessing and supply chain for aerospace applications (Gradl et al , 2022). Although past researchers have proved beneficial for AM process selection, there is barely any selection methodology based on the geometry, material capability and product quality expected by the user.…”

Section: Literature Searchmentioning

confidence: 99%

Selection methodology for additive manufacturing processes considering design, material, and manufacturability

Goala,

Sarkar

2023

RPJ

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Purpose One of the critical reasons for the nonacceptance of additive manufacturing (AM) processes is the lack of understanding and structured knowledge of design for additive manufacturing (DfAM). This paper aims to assist designers to select the appropriate AM technology for product development or redesign. Using the suggestion provided by the design assist tool, the user’s design alterations depend on their ability to interpret the suggestion into the design without affecting the design’s primary objective. Design/methodology/approach This research reports the development of a tool that evaluates the efficacy values for all seven major standard AM processes by considering design parameters, benchmark standards within the processes and their material efficacies. In this research, the tool provides analytical and visual approaches to suggestion and assistance. Seventeen design parameters and seven benchmarking standards are used to evaluate the proposed product and design quality value. The full factorial design approach has been used to evaluate the DfAM aspects, design quality and design complexity. Findings The outcome is evaluated by the product and design quality value, material suit and material-product-design (MPD) value proposed in this work for a comparative assessment of the AM processes for a design. The higher the MPD value, the better the process. The visual aspect of the evaluation uses spider diagrams, which are evaluated analytically to confirm the results’ appropriateness with the proposed methodology. Originality/value The data used in the database is assumed to make the study comprehensive. The output aims to help opt for the best process out of the seven AM techniques for better and optimized manufacturing. This, as per the authors’ knowledge, is not available yet.

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“…In contrast, the powder feeds to the melt pool directly in LDED (figure 2(b)) [25]. As shown in figure 2(c), compared with LPBF, LDED possesses unique advantages in the following aspects: (i) a magnitude higher deposition rate [26,27]; (ii) large-formation component manufacturing; (iii) local repair of high-value parts [28]; (iv) high flexibility in preparing gradient multi-materials [29]; and (v) higher flexibility when integrating with other technique (such as machining and rolling) [30].…”

Section: Introductionmentioning

confidence: 99%

Review on laser directed energy deposited aluminum alloys

Liu,

Chen,

Qiu

et al. 2024

Int. J. Extrem. Manuf.

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The lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing to process high-value Al parts. As a mainstream additive manufacturing technique, laser directed energy deposition (LDED) shows good scalability to meet requirements for large-format components manufacturing and repairing. However, LDED Al alloys are highly challenging due to the inherent poor printability (e.g., low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review gains a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, elements evaporation and resultant inferior mechanical properties (than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improve the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmarking mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. The future opportunities and perspectives in LDED high-performance Al alloys are also outlooked.

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Robust Metal Additive Manufacturing Process Selection and Development for Aerospace Components

Cited by 80 publications

References 328 publications

A 3D printable alloy designed for extreme environments

A 3D printable alloy designed for extreme environments

Selection methodology for additive manufacturing processes considering design, material, and manufacturability

Review on laser directed energy deposited aluminum alloys

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