Numerical investigation of laser deposited Al-based coatings on Ti-6Al-4V alloy
01 Feb 2018-
TL;DR: In this article, a simulation of the heat transfer and fluid dynamics of the melt pool is developed to predict the process parameters and reinforcement proportions on the clad geometry quality, and the results were compared to the experimental results for confirmation and validation.
Abstract: Titanium Alloy (Ti6Al4V) opened a wide range of useful applications in aerospace industries; these industries make use of different additive manufacturing (AM) techniques to obtain parts of different properties for different uses by this titanium alloy. Ttitanium alloy mainly stands out due to the properties such as high specific strength to weight ratio, and excellent corrosion resistance. Despite these benefits, the formation of defects such as pores and cracks play a vital role in the quality of the deposited coatings. The presence of these unwanted artefacts on laser deposited coatings depends on the melting, cooling and solidification of the melt pool. In this research, a simulation of the heat transfers and fluid dynamics of the melt pool is developed to predict the process parameters and reinforcement proportions on the clad geometry quality. The results were compared to the experimental results for confirmation and validation. Numerical modelling using COMSOL multiphysics 5.2 revealed the thermal behaviour of the coated samples.
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22 Jun 2018
31 citations
TL;DR: In this article, the effect of hybrid coating of Ti-Al-Cu on a grade five titanium alloy (Ti-6Al-4V) using laser metal deposition (LMD) process at different laser process parameters.
14 citations
25 Jan 2019
12 citations
TL;DR: This study investigated the metallurgical, mechanical properties and quality of coatings fabricated by direct laser metal deposition (DLMD) on Ti-6Al-4V, which were affected by the DLMD optimized process parameters.
6 citations
TL;DR: In this paper, a 3D numerical investigation was performed to predict micro-structural development and the sizes of the grain growth during the laser-deposition process, which had substantial effects in the overall resulting molten pool size and geometry size.
Abstract: Additive manufacturing is a commercially competitive manufacturing technique with the possibility of altering the entire perception of design and fabrication It offers suitable capabilities for the building and repairing applications in the aerospace industry, which usually requires high level of accuracy and customization of parts which usually use materials known to pose difficulties in fabrication such as titanium alloys The major factors that determine the formation of the dendritic structure are the thermal gradients within the substrate during cooling and the cooling rates The rapid cooling and input of heat locally during the laser deposition process resulted in metallurgical modifications such as the formation of a complete martensitic structure, a mixture of columnar grains and layer of bands During the deposition process, the metal solidified, and the developed model enabled predictability of microstructural development and the sizes of the grain growth The 3D numerical investigation provided clarification and had substantial effects in the prediction of the overall resulting molten pool size and geometry size
5 citations
References
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TL;DR: In this paper, the complexity and variety of fundamental phenomena in this material system with a focus on phase transformations and mechanical behaviour are discussed. And the challenges that lie ahead in achieving these goals are delineated.
1,797 citations
"Numerical investigation of laser de..." refers background in this paper
...These properties are obtained as a result of allotropic property possessed by these materials which is dependent on temperature and the effect of alloying on phase stability [1], [2]....
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21 Jan 2014-Materials Science and Engineering A-structural Materials Properties Microstructure and Processing
TL;DR: In this article, the results of using selective laser melting (SLM) to produce CP-Ti parts starting from powder with a wide grain size range up to 100μm were presented.
Abstract: Commercially pure titanium (CP-Ti) has received a great deal of attention in medical applications. Improvement of its mechanical properties plays a key role in enhancing the biomechanical compatibility of Ti implants, leading to avoid revision surgeries. Emerging advanced manufacturing technologies such as selective laser melting (SLM) is providing an ideal platform for producing components with almost no geometric constraints and is economically feasible down to a batch size of one. This study presents the results of using SLM to produce CP-Ti parts starting from powder with a wide grain size range up to 100 μm. Accurate manipulation of SLM manufacturing parameters were applied to produce nearly full dense (>99.5%) CP-Ti parts without any post-treatments. Compared with the properties of those manufactured by traditional processing technologies, the microhardness, compressive, and tensile strengths of SLM-processed CP-Ti parts have been improved to 261 Hv, 1136 MPa, and 757 MPa, respectively, due to the formation of refined martensitic α′ grains during SLM. The optimal manufacturing parameters could enhance the strength and hardness of CP-Ti and yet maintaining the ductility of titanium. Fractography study of the tensile-failed SLM-processed specimens showed that incompletely melted particles and porosities caused early fracture in porous sample. Mixture of dimples and minor quasi-cleavage facets covered most fracture surface of full dense sample.
549 citations
"Numerical investigation of laser de..." refers background in this paper
...[5] reported that these setbacks can be addressed by employing laser deposition process which has the ability to enhance strength and microhardness....
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TL;DR: A model of production cost for two different Additive Manufacturing systems used commercially for the manufacture of end-use metal parts is constructed, suggesting that the observed deposition rates are not sufficient for the adoption of EBM and DMLS in high volume manufacturing applications.
463 citations
"Numerical investigation of laser de..." refers background in this paper
...Material engineers continue to develop new and existing fabrication techniques in pursuit of improving or entirely replacing the conventional energy intensive, environmentally hostile and expensive methods [6]-[9]....
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TL;DR: In this article, the authors highlight some of the key aspects regarding materials qualification needs across the additive manufacturing (AM) spectrum, including various process-, microstructure-, and fracture-modeling activities in addition to integrating these with lifing activities targeting specific components.
Abstract: This overview highlights some of the key aspects regarding materials qualification needs across the additive manufacturing (AM) spectrum. AM technology has experienced considerable publicity and growth in the past few years with many successful insertions for non-mission-critical applications. However, to meet the full potential that AM has to offer, especially for flight-critical components (e.g., rotating parts, fracture-critical parts, etc.), qualification and certification efforts are necessary. While development of qualification standards will address some of these needs, this overview outlines some of the other key areas that will need to be considered in the qualification path, including various process-, microstructure-, and fracture-modeling activities in addition to integrating these with lifing activities targeting specific components. Ongoing work in the Advanced Manufacturing and Mechanical Reliability Center at Case Western Reserve University is focusing on fracture and fatigue testing to rapidly assess critical mechanical properties of some titanium alloys before and after post-processing, in addition to conducting nondestructive testing/evaluation using micro-computerized tomography at General Electric. Process mapping studies are being conducted at Carnegie Mellon University while large area microstructure characterization and informatics (EBSD and BSE) analyses are being conducted at Materials Resources LLC to enable future integration of these efforts via an Integrated Computational Materials Engineering approach to AM. Possible future pathways for materials qualification are provided.
435 citations
"Numerical investigation of laser de..." refers methods in this paper
...In order to overcome or reduce the evolution of residual stresses and the resultant of their unwanted artefacts, modelling and simulation of laser cladding processes is a way to go instead of the time intensive and economic demanding trial and error methods [12]....
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TL;DR: In this article, the development of laser cladding for functional coatings with high wear resistance, good corrosion and oxidation resistance, and better medical biocompatibility is reviewed, and the existing problems and the corresponding solutions are discussed.
417 citations
"Numerical investigation of laser de..." refers background in this paper
...However, poor tribological and low microhardness properties possessed by these materials hinder the extent of applications where the above-mentioned properties are required [3], [4]....
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