Self-terminating etching process for automated support removal and surface finishing of additively manufactured Ti-6Al-4 V

Raikar, Subbarao; Heilig, Meredith; Mamidanna, Avinash; Hildreth, Owen

doi:10.1016/j.addma.2020.101694

Cited by 13 publications

(6 citation statements)

References 21 publications

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“…Although the associated thermal cycling/reheating of the WAAM process aided the reduction/healing of β-flecks/segregation via the solid-state diffusion and redistribution of solute, some residual segregation (β-flecks) remained in the Ti–3Al–8V–6Cr–4Mo–4Zr alloy after the WAAM processing [62]. The microstructures of the as-built L-PBF binary-phase titanium (Ti–6Al–4V) samples usually have a non-equilibrium martensite phase (α′ phase) and this phase has been acknowledged to negatively impair the tensile and fatigue properties of the as-built Ti–6Al–4V part [18,65]. In another study, the as-built WAAM Ti–6Al–4V sample was reported to have Widman-statten- α instead of the α′ -martensite due to a much slower solid-state transformation at the cooling rate of 10–20 K s –1 [66].…”

Section: Post-processing Treatments Of Ti Alloysmentioning

confidence: 99%

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: A review

Ojo

Taban

2023

Materials Science and Technology

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The application of Metal Additive Manufacturing (MAM) in the aerospace industry has been gaining attention. The poor surface quality of parts greatly limits the prospects of MAM-produced parts in the aerospace industry as fatigue performance hinges on a good surface finish and homogeneous microstructure. Post-processing treatments are important to improve the surface quality and the overall performance of MAM-produced parts during static and dynamic loadings. This paper provides a review of the current state of post-processing treatment options for MAM-produced parts. The advances in the post-processing treatments of MAM parts to improve fatigue strength, tensile strength, surface integrity and other properties of parts are reviewed. Future research prospects on metal additive manufacturing of aerospace parts are briefly expounded. Abbreviations: AM: Additive Manufacturing; CMT-WAAM: Cold Metal Transfer-Based Wire Arc Additive Manufacturing; CSD: Cold Spray Deposition; DA: Direct Aging; DED: Directed Energy Deposition; E: Elongation; EBAM: Wire-feed Electron Beam Additive Manufacturing; EBAM Electron Beam Additive Manufacturing; EBSD: Electron Back Scattered Diffraction; FRAM: Friction Rolling Additive Manufacturing; FSAM: Friction Stir Additive Manufacturing; FSP: Friction Stir Processing; HFDB: Hybrid Friction Diffusion Bonding; HIP: Hot Isostatic Pressing; HSA Homogenisation + Solution Treatment + Aging; IFSP: Interlayer Friction Stir Processing; IPF: Inverse Pole Figure; KAM: Kernel Average Misorientation; LAM: Laser Additive Manufacturing Process; LENS: Laser Engineered Net Shaping; LDM: Laser Deposition Manufacturing; L-PBF: Laser Powder Bed Fusion; MAM: Metal Additive Manufacturing; MTFS: Multi-track Multi-layer Friction Surfacing; O-WLAM: Wire Oscillating Laser Additive Manufacturing (O-WLAM); S: Solution Treatment; SA: Solution Treatment + aging; TEM: Transmission Electron Microscope; UAM: Ultrasonic Additive Manufacturing; UTS: Ultimate Tensile Strength; WAAM: Wire Arc Additive Manufacturing; YS: Yield Strength

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Section: Post-processing Treatments Of Ti Alloysmentioning

confidence: 99%

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: A review

Ojo

Taban

2023

Materials Science and Technology

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“…Extensive experimental investigations have been carried out in the MPBF to address shortcomings of the process (Gu and Shen, 2007; Mercelis and Kruth, 2006), to optimize process parameters for printed part mechanical properties (Bagherifard et al , 2018; Kim et al , 2018; Jung et al , 2019; Kuzminova et al , 2019; Tezel and Kovan, 2022) and to propose new postprocessing methods for MPBF parts (Lefky et al , 2017; Eslam et al , 2020; Raikar et al , 2020). In Table 2, the experimental work-related information is organized based on the material, quality issues targeted, method, machine and process parameters used to investigate their impact on MPBF part quality.…”

Section: Strategies For Mitigation Of Quality Issues In Metal Powder ...mentioning

confidence: 99%

Review of quality issues and mitigation strategies for metal powder bed fusion

Ravalji

Raval

2022

RPJ

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Purpose Selective laser melting and electron beam melting processes are well-known for the additive manufacturing of metal parts. Metal powder bed fusion (MPBF) is a common term for them. The MPBF process can empower the manufacturing of intricate shapes by reducing the use of special tools, shortening the supply chain and allowing small batches. However, the MPBF process suffers from many quality issues. In literature, several works are recorded for qualification of the MPBF part. The purpose of this study is to recollect those works done for quality control and report their helpful findings for further research and development. Design/methodology/approach A systematic literature review was conducted to highlight the major quality issues in the MPBF process and its root causes. Further, the works reported in the literature for mitigation of these issues are classified and discussed in five categories: experimental investigation, finite element method-based numerical models, physics-based analytical models, in-situ control using artificial intelligence (AI) and machine learning (ML) methods and statistical approaches. A comparison is also prepared among these strategies based on their suitability and limitations. Additionally, improvements in MPBF printers are pointed out to enhance the part quality. Findings Analytical models require less computational time to simulate the MPBF process and need a smaller number of experiments to confirm the results. They can be used as an efficient process parameter planning tool to print metal parts for noncritical applications. The AI-ML based quality control is also suitable for MPBF processes as it can control many processing parameters that may affect the quality of the MPBF part. Moreover, capabilities of MPBF printers like thinner layer thickness, smaller beam diameter, multiple lasers and high build temperature range can help in quality control. Research limitations/implications This study converts the piecemeal data on MPBF part qualification methods into interesting information and presents it in tabular form under each strategy. This tabular information provides the basis for further quality improvement efforts in the MPBF process. Originality/value This study references researchers and practitioners on recent quality control efforts and their significant findings for a better quality of MPBF part.

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“…Understanding the corrosion kinetics of sulfur-metal systems is of great interest for preventing or mitigating the detrimental effects of corrosion in industries such as oil and gas power plants [1,2]. Corrosion kinetics are also of interest to the Additive Manufacturing (AM) industry, which uses controlled corrosion to remove metal support structures and improve the surface finish and fatigue performance of printed parts [3][4][5][6]. The Hildreth Group recently developed techniques that use sulfidizing corrosive environments for post-processing additively manufactured Ti-6Al-4V (Ti64) parts [5].…”

Section: Introductionmentioning

confidence: 99%

“…Corrosion kinetics are also of interest to the Additive Manufacturing (AM) industry, which uses controlled corrosion to remove metal support structures and improve the surface finish and fatigue performance of printed parts [3][4][5][6]. The Hildreth Group recently developed techniques that use sulfidizing corrosive environments for post-processing additively manufactured Ti-6Al-4V (Ti64) parts [5]. In these techniques, a 3D-printed metal part is heat-treated in a sulfur environment to form sulfide scales with the top 50-100 µm of the part's surface.…”

Section: Introductionmentioning

confidence: 99%

Sulfidation kinetics of titanium and Ti-6Al-4V with elemental sulfur

Raikar

DiGregorio

Hildreth

2023

Corrosion Engineering, Science and Technology

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The sulfidation kinetics of titanium and Ti-6Al-4V (Ti64) using elemental sulfur were studied by measuring the amount of metal consumed instead of the change in mass or scale thickness. This metal consumption approach combines the parabolic oxidation law, Arrhenius equation, and Pilling-Bedworth ratio to determine the apparent activation energy and the pre-exponential factor of consumption of Ti64 during sulfidation. The estimations of apparent activation energy and preexponential factor were 110.4 kJ•mol −1 and 1.3 × 10 −9 m 2 s −1 for the titanium-sulfur, and 116.2 kJ•mol −1 and 1.2 × 10 −9 m 2 s −1 for the Ti64-sulfur system. Finally, a material removal predictor was developed to predict the amount of Ti64 consumed for a given sulfidation temperature and time.

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Self-terminating etching process for automated support removal and surface finishing of additively manufactured Ti-6Al-4 V

Cited by 13 publications

References 21 publications

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: A review

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: A review

Review of quality issues and mitigation strategies for metal powder bed fusion

Sulfidation kinetics of titanium and Ti-6Al-4V with elemental sulfur

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Self-terminating etching process for automated support removal and surface finishing of additively manufactured Ti-6Al-4 V

Cited by 13 publications

References 21 publications

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: A review

Post-processing treatments–microstructure–performance interrelationship of metal additive manufactured aerospace alloys: A review

Review of quality issues and mitigation strategies for metal powder bed fusion

Sulfidation kinetics of titanium and Ti-6Al-4V with elemental sulfur

Contact Info

Product

Resources

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Self-terminating etching process for automated support removal and surface finishing of additively manufactured Ti-6Al-4 V