Next generation, additively-manufactured metallic parts will be designed with application-optimized geometry, composition, and functionality. Manufacturers and researchers have investigated various techniques for increasing the reliability of the metal-AM process to create these components, however, understanding and manipulating the complex phenomena that occurs within the printed component during processing remains a formidable challenge-limiting the use of these unique design capabilities. Among various approaches, thermomechanical modeling has emerged as a technique for increasing the reliability of metal-AM processes, however, most literature is specialized and challenging to interpret for users unfamiliar with numerical modeling techniques. This review article highlights fundamental modeling strategies, considerations, and results, as well as validation techniques using experimental data. A discussion of emerging research areas where simulation will enhance the metal-AM optimization process is presented, as well as a potential modeling workflow for process optimization. This review is envisioned to provide an essential framework on modeling techniques to supplement the experimental optimization process.

Invited Review Article: Metal-additive manufacturing — Modeling strategies for application-optimized designs

A critical review on dissimilar welds joint between martensitic and austenitic steel for power plant application

The columnar to equiaxed transition (CET) of grain structures associated with processing conditions has been observed during metallic additive manufacturing (AM). However, the formation mechanisms of these grain structures have not been well understood under rapid solidification conditions, especially for AM of superalloys. This paper aims to uncover the underlying mechanisms that govern the CET of AM metals, using a well-tested multiscale phase-field model where heterogeneous nucleation, grain selection and grain epitaxial growth are considered. Using In718 as an example, the simulated results show that the CET is critically controlled by the undercooling, involving constitutional supercooling, thermal and curvature undercoolings in the melt pool, which dictates the extent of heterogeneous nucleation with respect to the grain epitaxial growth during rapid solidification.

Insight into the mechanisms of columnar to equiaxed grain transition during metallic additive manufacturing

Aerospace is a key market driver for the advancement of additive manufacturing (AM) due to the huge demands in high-mix low-volume production of high-value parts, integrated complex part geometries and simplified fabrication workflow. Rapid and significant progress has been made in the laser additive manufacturing (LAM) of aeroengine materials, including the advanced high-strength steels, nickel-based superalloys and titanium-based alloys. Despite the extensive investigation of these three families of materials by the research community, there is a lack of comprehensive review on LAM of high strength steels, and existing gaps in published reviews on Ti-based alloys and Ni-based superalloys. Furthermore, although emerging materials such as high/medium entropy alloys and heterostructured materials exhibit promising mechanical performance, rigorous characterization, testing, qualification, and certification are still required before actual application in engine parts. Thus, it is still important and relevant to have a deep understanding on the relationship between process parameters – microstructures – mechanical properties in these widely used aeroengine materials, to drive the development of superior high-value alloys. This review aims to provide a critical and in-depth evaluation of laser powder bed fusion (LPBF) and laser directed energy deposition (LDED) technologies of the mentioned aeroengine materials. The review will summarize the material properties, performance envelops and outlines the research gaps of these aeroengine materials. Furthermore, perspectives on research opportunities, materials development, and new R&D approaches of LAM for the aeroengine materials are also highlighted.

Progress and perspectives in laser additive manufacturing of key aeroengine materials

Additive manufacturing (AM) offers customization of the microstructures and mechanical properties of fabricated components according to the material selected and process parameters applied. Selective laser melting (SLM) is a commonly-used technique for processing high strength aluminum alloys. The selection of SLM process parameters could control the microstructure of parts and their mechanical properties. However, the process parameters limit and defects obtained inside the as-built parts present obstacles to customized part production. This study investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts according to the mutual connection between the microstructure characteristics and mechanical properties. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate internal microstructure defects. The behavior of the mechanical properties of parts was presented through regression models generated from the design of experiment (DOE) analysis for the results of hardness, ultimate tensile strength, and yield strength. A comparison between the results obtained and those reported in the literature is presented to illustrate the influence of process parameters, build environment, and powder characteristics on the quality of parts produced. The results obtained from this study could help to customize the part’s quality by satisfying their design requirements in addition to reducing as-built defects which, in turn, would reduce the amount of the post-processing needed.

https://www.mdpi.com/1996-1944/12/1/12/pdf

The Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al6061 and AlSi10Mg Alloys

Variability in the mechanical properties of additively manufactured metal parts is a key concern for their application in service. One of the parameters affecting the above-mentioned property is solidification texture which is driven by scan patterns and other process variables. Understanding of how these textures arise in the AM process can provide a pathway to control these features which ultimately decide the final structural material properties. In this work, a Cellular Automata (CA) based two-dimensional microstructure model is formulated and implemented to understand grain evolution in AM. Grain evolution in multilayer depositions using various scan patterns in Directed Energy Deposition (DED), Metal Laser Sintering/Selective Laser Melting (MLS/SLM), and Electron Beam Melting (EBM) is presented and qualitatively compared with reported literature. Results show strong correlation of scan patterns with evolving grain orientations. Variability in grain size and orientation evolution during SLM and EBM processing of metallic materials showed direct influence by exposure to different cooling rates and thermal gradients. The similarities between the simulated and reported results lead us to conclude CA based modeling for predicting grain orientation and size in metal AM processes is useful for prediction of continuum level structural properties at global and local length scales.

Understanding grain evolution in additive manufacturing through modeling

The melt pool characteristics in terms of size and shape and the porosity development in laser powder bed fusion–processed Inconel 718 were investigated to determine how laser power and scan speed influence the porosity in the microstructure. The melt pool characteristics developed with both single-track and multilayer bulk laser deposition were evaluated. It was found that the melt pool characteristic is critical for the porosity development. It is shown that the porosity fraction and pore shape change depending on the melt pool size and shape. This result is explained based on the local energy density of a laser during the process. High-density (> 99%) Inconel 718 samples were achieved over a wide range of laser energy densities (J/mm2). A careful assessment shows that the laser power and scan speed affect differently in developing the pores in the samples. The porosity decreased rapidly with the increase in laser power while it varied linearly with the scan speed. A proper combination, however, led to fully dense samples. The study reveals an optimum condition in terms of laser power and scan speed that can be adopted to fabricate high-density Inconel 718 parts using laser powder bed fusion–based additive manufacturing process.

Influence of laser processing parameters on porosity in Inconel 718 during additive manufacturing

Dissimilar welds between ferritic creep-resistant steels and austenitic stainless steels in power plant service are known to fail prematurely due to a large difference in their thermal coefficient of expansion. To address this problem, in the current work, modified 9Cr-1Mo steel (P91) and austenitic stainless steel (AISI 304) transition joints were produced using friction welding employing three interlayers: Inconel 625, Inconel 600, and Inconel 800 H. These interlayers were friction welded one over another on P91 alloy, which was finally friction welded to AISI 304. The joints produced with single and three interlayers were subjected to creep rupture tests at different temperatures and stress levels. The creep test results demonstrated that the proposed approach can help realize striking improvements in creep performance of P91/AISI 304 dissimilar metal welds. Further, analysis of creep resulted in a stress exponent (n) of 3 by incorporating the concept of threshold stress which suggested the creep deformation mechanism to be viscous glide due to solute drag. Creep rupture data was also analyzed using Monkman-Grant relationship and creep damage tolerance factor (λ). Results indicated that the damage mechanism is due to cavity growth by the combined effect of power law and diffusion creep.

/pdf/creep-behavior-of-dissimilar-metal-weld-joints-between-p91-2vcxt8xrbm.pdf

Creep behavior of dissimilar metal weld joints between P91 and AISI 304

Microstructure evolution and hardness were evaluated at the interface of two friction-welded transition joints between P91 and AISI 304 fabricated applying Inconel interlayers, viz. single-interlayer weld (P91/IN600/AISI304) and three-interlayer weld (P91/IN625/IN600/IN800H/AISI304). The welds were subjected to post-weld heat treatment at 1023 K for 1 h followed by air cooling and a long-term exposure at 973 K for 100, 250, and 500 h. A soft zone with the absence of lath martensite was noticed in both the welds which was located at the intercritical heat-affected zone of the welds. This zone was found to be extending with time toward the fine grain heat-affected zone by carbide precipitation and coarsening at the grain boundaries. Soft zone formation at the interface of the welds was found to be due to carbon diffusion. The presence of high-nickel-content alloy at the interface was proven to be beneficial in stopping carbon diffusion at the interface. Though soft zones existed in both the welds, better creep rupture life was observed for three-interlayer welds. Finite element analysis of these weld joints was performed for thermal loading followed by tensile loading. The results from this analysis indicated that thermal expansion also plays an important role in the failures of these dissimilar weld joints by creating high stress at the interface due to incompatibility.

Javed Akram

Papers

Understanding grain evolution in additive manufacturing through modeling

Influence of laser processing parameters on porosity in Inconel 718 during additive manufacturing

Creep behavior of dissimilar metal weld joints between P91 and AISI 304

Dissimilar Metal Weld Joints of P91/Ni Alloy: Microstructural Characterization of HAZ of P91 and Stress Analysis at the Weld Interfaces

Low temperature friction stir welding of P91 steel