Sandwich structure printing of Ti-Ni-Ti by directed energy deposition

Since shaft parts operate under harsh environments for a long time, many critical parts suffer from corrosion, wear and other problems, leading to part failure and inability to continue in service. It is imperative to repair failed parts and increase their service life. An orthogonal experimental scheme is designed to numerically simulate the process of laser cladding of Inconel 718 alloy powder on 4140 alloy structural steel based on the ANSYS simulation platform, derive the relationship equation of cladding layer thickness according to the heat balance principle, establish a finite element model, couple three modules of temperature field, stress field and fluid field, and analyze different modules to realize the monitoring of different processes of laser cladding. The optimal cladding parameters were laser power 1000 W, scanning speed 15 rad/s, spot radius 1.5 mm, thermal stress maximum value of 696 Mpa, residual stress minimum value of 281 Mpa, and the degree of influence of three factors on thermal stress maximum value: laser power > spot radius > scanning speed. The pool in the melting process appears to melt the “sharp corner” phenomenon, the internal shows a double vortex effect, with a maximum flow rate of 0.02 m/s. The solidification process shows a different shape at each stage due to the different driving forces. In this paper, multi-field-coupled numerical simulations of the laser cladding process were performed to obtain optimal cladding parameters with low residual stresses in the clad layer. The melt pool grows and expands gradually during melting, but the laser loading time is limited, and the size and shape of the melt pool are eventually fixed, and there is a vortex flowing from the center to both sides of the cross-section inside the melt pool, forming a double vortex effect. The solidification is divided into four stages to complete the transformation of the liquid phase of the melt pool to the solid phase, and the cladding layer is formed. The multi-field-coupled numerical simulation technique is used to analyze the temperature, stress and fluid fields to provide a theoretical basis for the residual stress and surface quality of the clad layer for subsequent laser cladding experiments.

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“…It is commonly used in additive manufacturing for repairing failed parts, strengthening surfaces, etc. [ 15 , 16 ].…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts

Zhao

Yang

et al. 2023

Micromachines

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“…On the other hand, TiAl alloys have low roomtemperature plasticity, fracture toughness, and poor high-temperature oxidation resistance, limiting their practical application [4]. To improve the properties of TiAl alloys, Nb and Zr have been added to enhance their room-temperature plasticity and high-temperature oxidation resistance [5]. Among the TiAl-based alloys, Ti 2 AlNb alloy has attracted attention for its high-temperature strength, good anti-oxidation properties, and low density, with long-term service temperatures of up to 923 K-973 K [6].…”

Section: Introductionmentioning

confidence: 99%

Microstructural Evolution and Mechanical Properties of Ti2AlNb/GH99 Superalloy Brazed Joints Using TiZrCuNi Amorphous Filler Alloy

Cai

Liu

et al. 2023

Aerospace

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Dissimilar materials brazing of Ti2AlNb alloy to GH99 superalloy is of great pragmatic importance in the aerospace field, especially the lightweight space aircraft components manufacturing. In this work, TiZrCuNi amorphous filler alloy was used as brazing filler, and experiments were carried out at different brazing temperatures and times to investigate the changes in interfacial structures and properties of the joints. The typical interfacial microstructure was Ti2AlNb alloy/B2/β/Ti2Ni (Al, Nb) + B2/β + (Ti, Zr)2(Ni, Cu) + (Ti, Zr)(Ni, Cu)/(Cr, Ni, Ti) solid solution + (Ni, Cr) solid solution/GH99 superalloy when being brazed at 1000 °C for 8 min. The interfacial microstructure of the joints was influenced by diffusion and reaction between the filler alloy and the parent metal. The prolongation of brazing process parameters accelerated the diffusion and reaction of the liquid brazing alloy into both parent metals, which eventually led to the aggregation of (Ti, Zr)2(Ni, Cu) brittle phase and increased thickness of Ti2Ni (Al, Nb) layer. According to fracture analyses, cracks began in the Ti2Ni (Al, Nb) phase and spread with it as well as the (Ti, Zr)2(Ni, Cu) phase. The joints that were brazed at 1000 °C for 8 min had a maximum shear strength of ~216.2 MPa. Furthermore, increasing the brazing temperature or extending the holding time decreased the shear strength due to the coarse Ti2Ni (Al, Nb) phase and the continuous (Ti, Zr)2(Ni, Cu) phase.

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“…As metal product manufacturing costs have increased, sustainable manufacturing techniques for producing complex shapes with high strength-to-weight ratios, that produce limited waste, have emerged [1,2]. In recent years, additive manufacturing (AM) techniques have been established in many areas using 3D printing parts fabricated from metals and alloys [3,4] and other materials [5][6][7] built up in layers until they have reached their finished part shape.…”

Section: Introductionmentioning

confidence: 99%

Additively Manufactured Parts from AA2011-T6 Large-Diameter Feedstocks Using Friction Stir Deposition

et al. 2023

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The current work investigates the possibility of fabricating additive manufacturing products in solid-state form, from AA2011-T6 of 40 mm diameter rods as a feedstock, using an additive friction stir deposition (A-FSD) technique. The use of large diameter feedstocks, especially high-strength aluminum alloys (2XXX series), is a challenge, as it necessitates high power and the critical selection of the optimal A-FSD parameters, such as feed rate and spindle rotation speed. The study included applying a wide range of spindle rotation speeds, ranging from 400 to 1200 rpm, at three levels of feeding rates of 1, 3, and 5 mm/min. The AA2011-T6 friction stir deposited parts (FSDPs) were visually evaluated. This was followed by an examination of macrostructures through the thickness of the fabricated specimens. The characterization of microstructures was also carried out using optical microscopy and a scanning electron microscope equipped with advanced EDS analysis. Furthermore, the mechanical properties in terms of hardness and compressive strength of the AA2011-T6 base material (BM) and deposited materials were evaluated. Sound, additively manufactured products were successfully fabricated from 40 mm diameter AA2011-T6 feedstocks using the suggested deposition variables of 600 and 800 rpm spindle speeds and feeding rates of 1, 3, and 5 mm/min. The results indicated that the spindle speed and feeding rate govern the quality of the FSDPs. Furthermore, the axial load during the A-FSD process increased with increasing these parameters. In comparison to the AA2011-T6 BM, the additively deposited materials showed a refined grain structure and uniform dispersion of the fragment precipitates in their continuous multi-layers. The reduction ratio in grain size attains 71.56%, 76%, and 81.31% for the FSDPs processed at 800 rpm spindle speed and feeding rates of 1, 3 and 5 mm/min, respectively, compared to the grain size of BM. The Al2Cu and Al7Cu2Fe intermetallics are detected in the AA2011-T6 BM, and their deposited parts are in different shapes of spherical, almost spherical, irregular, and rod-like shapes. The compressive strength and hardness of the deposited parts increased with increasing spindle speed and feeding speeds. At a spindle speed of 800 rpm and a 5 mm/min feeding rate, the higher hardness and compressive strength gained were 85% and 93%, respectively, from that of the AA2011-T6 feedstock.

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Sandwich structure printing of Ti-Ni-Ti by directed energy deposition

Cited by 21 publications

References 39 publications

Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts

Numerical Simulation Study of Multi-Field Coupling for Laser Cladding of Shaft Parts

Microstructural Evolution and Mechanical Properties of Ti2AlNb/GH99 Superalloy Brazed Joints Using TiZrCuNi Amorphous Filler Alloy

Additively Manufactured Parts from AA2011-T6 Large-Diameter Feedstocks Using Friction Stir Deposition

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