Selective compositional range exclusion via directed energy deposition to produce a defect-free Inconel 718/SS 316L functionally graded material

Kim, Sang Hoon; Lee, Hoyoung; Yeon, Si Mo; Aranas, Clodualdo; Choi, Kyunsuk; Yoon, Jongcheon; Yang, Seung Weon; Lee, Hyub

doi:10.1016/j.addma.2021.102288

Cited by 25 publications

(9 citation statements)

References 59 publications

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“…First, SUS304L/IN625 FGM with a size of 25 × 45 × 2 mm was deposited on the SUS304L substrate by changing the mixing ratio of 25 wt% per 2 layers using LMD. The mixing ratio was selected to exclude the composition range where defects were found in previous studies [ 28 ], and the processing time was minimized by minimizing the number of layers. In the WAAM experiment, 28 layers of Inconel 625 were deposited using the fabricated FGM as a substrate, and Figure 5 shows the LMD-WAAM sample.…”

Section: Methodsmentioning

confidence: 99%

Effect of Functionally Graded Material (FGM) Interlayer in Metal Additive Manufacturing of Inconel-Stainless Bimetallic Structure by Laser Melting Deposition (LMD) and Wire Arc Additive Manufacturing (WAAM)

2023

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Bimetallic structures manufactured by direct deposition have a defect due to the sudden change in the microstructure and properties of dissimilar metals. The laser metal deposition (LMD)-wire arc additive manufacturing (WAAM) process can alleviate the defect between two different materials by depositing the functionally graded material (FGM) layer, such as a thin intermediate layer using LMD and can be used to fabricate bimetallic structures at high deposition rates with relatively low costs using WAAM. In this study, the LMD-WAAM process was performed, and the microstructure of the fabricated bimetallic structure of IN625-SUS304L was investigated. The microstructure of the FGM zone of the LMD-WAAM sample was mainly fine equiaxed dendrite morphologies. In contrast, coarse columnar dendrite morphologies constituted the WAAM zone. The composition of the major alloying elements of the LMD-WAAM sample gradually changed with the height of the deposited layer. The microhardness of the LMD-WAAM sample tended to increase with an increasing Inconel content. In the case of the LMD-WAAM sample, the fracture occurred near the interface between 25% IN625 and 0% IN625; in the WAAM sample, the final fracture occurred in SUS304L near the interface. The tensile strength of the LMD-WAAM samples was inversely proportional to the laser power. The results showed that the LMD-WAAM samples had 8% higher tensile strength than the samples fabricated using only WAAM.

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Section: Methodsmentioning

confidence: 99%

Effect of Functionally Graded Material (FGM) Interlayer in Metal Additive Manufacturing of Inconel-Stainless Bimetallic Structure by Laser Melting Deposition (LMD) and Wire Arc Additive Manufacturing (WAAM)

2023

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“…The melt is undercooled, and with the development of eutectic cells, a negative temperature field forms ahead of the solid-liquid surface [36,42]. From the microstructure analysis in Figure 5 and Video S1, there are partitioning components, especially Si, enriched in the cellular boundaries, destabilising the interface and causing high constitutional undercooling [43]. Eutectic branches develop, driven by thermal and constitutional undercooling.…”

Section: Microstructure Evolutionmentioning

confidence: 99%

Microstructure and Mechanical Properties of Ultrafine Quaternary Al-Cu-Si-Mg Eutectic Alloy

Cai

Cantor

Tong

et al. 2021

Metals

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The microstructure evolution and mechanical properties of quaternary Al-Cu-Si-Mg eutectic alloy prepared via arc melting and suction casting were studied. This alloy exhibits a single endothermic DSC peak with a melting temperature of 509 °C upon heating, suggesting a eutectic reaction. The cast alloy microstructure consisted of four phases, α-Al, Al2Cu (), Si and Al4Cu2Mg8Si7 (Q), in the eutectic cells and also in the nano-scale anomalous eutectic in the intercellular regions. The eutectic cells show different morphologies in different parts of the sample. Well-defined orientation relationships between the α-Al, Al2Cu, and Q phases were found in the eutectic cell centres, while decoupled growth of Q phase occurred at the cell boundaries. The bimodal microstructure exhibits excellent compressive mechanical properties, including a yield strength of 835 ± 35 MPa, a fracture strength of ~1 GPa and a compressive fracture strain of 4.7 ± 1.1%. The high strength is attributed to a combination of a refined eutectic structure and strengthening from multiple hard phases.

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“…They reported that the best combination of mechanical properties (tensile strength of 527.05 MPa and elongation of 26.21%) were obtained with a composition change step of 10%. In another study, Kim et al 14 observed that the formation of defects (pores and cracks) occurs in certain chemical composition ranges of the SS316L/IN718 structure affected by ceramic oxides and their subsequent propagation in the direction of intermetallic and carbide compounds. Moreover, thermal and residual stresses concentrated at the grain boundaries exacerbated the formation of these defects.…”

Section: Introductionmentioning

confidence: 99%

Printability and microstructure of directed energy deposited SS316l-IN718 multi-material: numerical modeling and experimental analysis

Ghanavati

Naffakh-Moosavy

Moradi

et al. 2022

Sci Rep

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In the present paper, the interrelated aspects of additive manufacturing-microstructure-property in directed energy deposition of SS316L-IN718 multi-material were studied through numerical modeling and experimental evaluation. The printability concept and solidification principles were used for this purpose. The printability analysis showed that the SS316L section is more susceptible to composition change and lack of fusion, respectively due to the high equilibrium vapor pressure of manganese and the more efficient heat loss in the initial layers. However, the IN718 section is more prone to distortion due to the formation of a larger melt pool, with a maximum thermal strain of 3.95 × 10−3 in the last layer. As the process continues, due to heat accumulation and extension of the melt pool, the cooling rate decreases and the undercooling level increases, which respectively result in coarser microstructure and more instability of solidification front in the build direction, as also observed in the experimental results. The difference is that the dendritic microstructure of the IN718 section, due to the eutectic reaction L → γ + Laves, is formed on a smaller scale compared to the cellular microstructure of the SS316L section. Also, the decrease in cooling rate caused the secondary phase fraction in each section (delta ferrite in SS316L and Laves in IN718) to increase almost linearly. However, the hardness calculation and measurement showed similarly, even though with the transition from SS316L to IN718 the hardness is significantly increased due to higher yield strength of the matrix and the presence of Laves intermetallic phase (~ 260 HV0.3), the hardness in each section decreases slightly due to the coarsening of the microstructure from the initial layer to the final.

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Selective compositional range exclusion via directed energy deposition to produce a defect-free Inconel 718/SS 316L functionally graded material

Cited by 25 publications

References 59 publications

Effect of Functionally Graded Material (FGM) Interlayer in Metal Additive Manufacturing of Inconel-Stainless Bimetallic Structure by Laser Melting Deposition (LMD) and Wire Arc Additive Manufacturing (WAAM)

Effect of Functionally Graded Material (FGM) Interlayer in Metal Additive Manufacturing of Inconel-Stainless Bimetallic Structure by Laser Melting Deposition (LMD) and Wire Arc Additive Manufacturing (WAAM)

Microstructure and Mechanical Properties of Ultrafine Quaternary Al-Cu-Si-Mg Eutectic Alloy

Printability and microstructure of directed energy deposited SS316l-IN718 multi-material: numerical modeling and experimental analysis

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