In situ microstructure analysis of Inconel 625 during laser powder bed fusion
TL;DR: In this article, high-energy X-ray diffraction experiments were carried out to illuminate the formation and evolution of microstructural features during laser powder bed fusion, and the diffraction patterns yielded results regarding texture, lattice defects, recrystallization, and chemical segregation.
Abstract: Laser powder bed fusion is an additive manufacturing process that employs highly focused laser radiation for selective melting of a metal powder bed. This process entails a complex heat flow and thermal management that results in characteristic, often highly textured microstructures, which lead to mechanical anisotropy. In this study, high-energy X-ray diffraction experiments were carried out to illuminate the formation and evolution of microstructural features during LPBF. The nickel-base alloy Inconel 625 was used for in situ experiments using a custom LPBF system designed for these investigations. The diffraction patterns yielded results regarding texture, lattice defects, recrystallization, and chemical segregation. A combination of high laser power and scanning speed results in a strong preferred crystallographic orientation, while low laser power and scanning speed showed no clear texture. The observation of a constant gauge volume revealed solid-state texture changes without remelting. They were related to in situ recrystallization processes caused by the repeated laser scanning. After recrystallization, the formation and growth of segregations were deduced from an increasing diffraction peak asymmetry and confirmed by ex situ scanning transmission electron microscopy.
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TL;DR: In this article , the influence of the build orientation and the texture on the microstructure and consequently the mechanical anisotropy of as-built Inconel 718 was demonstrated.
Abstract: Abstract The manufacturability of metallic alloys using laser-based additive manufacturing methods such as laser powder bed fusion has substantially improved within the last decade. However, local melting and solidification cause hierarchically structured and crystallographically textured microstructures possessing large residual stress. Such microstructures are not only the origin of mechanical anisotropy but also pose metrological challenges for the diffraction-based residual stress determination. Here we demonstrate the influence of the build orientation and the texture on the microstructure and consequently the mechanical anisotropy of as-built Inconel 718. For this purpose, we manufactured specimens with [001]/[011]-, [001]- and [011]/[ $$\overline{1} {\text{11}}$$ 1 ¯ 11 ]-type textures along their loading direction. In addition to changes in the Young’s moduli, the differences in the crystallographic textures result in variations of the yield and ultimate tensile strengths. With this in mind, we studied the anisotropy on the micromechanical scale by subjecting the specimens to tensile loads along the different texture directions during in situ neutron diffraction experiments. In this context, the response of multiple lattice planes up to a tensile strain of 10% displayed differences in the load partitioning and the residual strain accumulation for the specimen with [011]/[ $$\overline{1} {\text{11}}$$ 1 ¯ 11 ]-type texture. However, the relative behavior of the specimens possessing an [001]/[011]- and [001]-type texture remained qualitatively similar. The consequences on the metrology of residual stress determination methods are discussed.
5 citations
TL;DR: In this article , the authors evaluated the corrosion properties of different samples coated by the laser-cladding method to find the optimal laser parameters, and found that the laser power directly correlates with pitting corrosion and defects on the surface of the samples.
Abstract: This study aimed to evaluate the corrosion properties of different samples coated by the laser-cladding method to find the optimal laser parameters. Thereby, potentiodynamic polarization (Tafel) and electrochemical impedance tests were performed to assess the corrosion resistance of coated samples. Consequently, the corrosion morphology of tested samples was inspected by scanning electron microscopy. The results demonstrated that the laser power directly correlates with pitting corrosion and defects on the surface of the samples. Moreover, when molybdenum and chromium ions are increased in the electrolyte solution, the passive and protective layers are more durable, as the ions are sited within the holes and defects, reducing the surface corrosion rate.
4 citations
TL;DR: In this article , the influence of substrate pre-heating and a complex scan pattern on the strain and internal stress progression during the manufacturing of Inconel 625 parts is investigated, and phase transitions during melting and solidification of an intermetallic γ-TiAl based alloy are examined.
Abstract: The high flux combined with the high energy of the monochromatic synchrotron radiation available at modern synchrotron facilities offers vast possibilities for fundamental research on metal processing technologies. Especially in the case of laser powder bed fusion (LPBF), an additive manufacturing technology for the manufacturing of complex-shaped metallic parts, in situ methods are necessary to understand the highly dynamic thermal, mechanical, and metallurgical processes involved in the creation of the parts. At PETRA III, Deutsches Elektronen-Synchrotron, a customized LPBF system featuring all essential functions of an industrial LPBF system, is used for in situ x-ray diffraction research. Three use cases with different experimental setups and research questions are presented to demonstrate research opportunities. First, the influence of substrate pre-heating and a complex scan pattern on the strain and internal stress progression during the manufacturing of Inconel 625 parts is investigated. Second, a study on the nickel-base superalloy CMSX-4 reveals the formation and dissolution of γ' precipitates depending on the scan pattern in different part locations. Third, phase transitions during melting and solidification of an intermetallic γ-TiAl based alloy are examined, and the advantages of using thin platelet-shaped specimens to resolve the phase components are discussed. The presented cases give an overview of in situ x-ray diffraction experiments at PETRA III for research on the LPBF technology and provide information on specific experimental procedures.
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TL;DR: The MATLAB toolbox MTEX as discussed by the authors provides a unique way to represent, analyse and interpret crystallographic preferred orientation, i.e. texture based on integral (pole figure) or individual orientation (EBSD) measurements.
Abstract: The MATLAB™ toolbox MTEX provides a unique way to represent, analyse and interpret crystallographic preferred orientation, i.e. texture, based on integral (“pole figure”) or individual orientation (“EBSD”) measurements. In particular, MTEX comprises functions to import, analyse and visualize diffraction pole figure data as well as EBSD data, to estimate an orientation density function from either kind of data, to compute texture characteristics, to model orientation density functions in terms of model functions or Fourier coefficients, to simulate pole figure or EBSD data, to create publication ready plots, to write scripts for multiple use, and others. Thus MTEX is a versatile free and open-source software toolbox for texture analysis and modeling.
1,836 citations
TL;DR: In this article, a review of additive manufacturing (AM) techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid-state precipitation, mechanical properties and post-processing metallurgy.
Abstract: Additive manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire or sheets in a process that proceeds layer by layer. Many techniques (using many different names) have been developed to accomplish this via melting or solid-state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid-state precipitation, mechanical properties and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Only a few alloys have been developed for commercial production, but recent efforts are presented as a path for the ongoing development of new materials for AM processes.
1,713 citations
TL;DR: Selective laser melting (SLM) is a particular rapid prototyping, 3D printing, or additive manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders as mentioned in this paper.
Abstract: Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component is built by selectively melting and fusing powders within and between layers. The SLM technique is also commonly known as direct selective laser sintering, LaserCusing, and direct metal laser sintering, and this technique has been proven to produce near net-shape parts up to 99.9% relative density. This enables the process to build near full density functional parts and has viable economic benefits. Recent developments of fibre optics and high-power laser have also enabled SLM to process different metallic materials, such as copper, aluminium, and tungsten. Similarly, this has also opened up research opportunities in SLM of ceramic and composite materials. The review presents the SLM process and some of the common physical phenomena associated with this AM technology. It then focuses on the following a...
1,455 citations
TL;DR: In this article, the experimental observation of keyhole-mode laser melting in a laser powder-bed fusion additive manufacturing setting for 316L stainless steel is presented, and the conditions required to transition from conduction controlled melting to keyholemode melting are identified.
981 citations