Showing papers on "Microstructure published in 2016"

Effect of heat treatment on AlSi10Mg alloy fabricated by selective laser melting: Microstructure evolution, mechanical properties and fracture mechanism

Abstract: The present paper systematically investigated the influence of solution and artificial aging heat treatments on the microstructures and mechanical properties of SLM-produced AlSi10Mg alloy parts. Due to the high cooling rate of SLM, an ultrafine eutectic microstructure in the as-built samples is characterized by spherical nano-sized network eutectic Si embedded in the Al matrix, which gives rise to significantly better tensile properties and Vickers micro-hardness. The solubility of Si atom in the Al matrix of as-built SLM samples is calculated to be 8.89 at%. With the increase in the solution temperature, the solubility decreases rapidly. The artificial aging causes the further decrease of the solubility of Si atoms in the Al matrix. Upon solution heat treatment, Si atoms are rejected from the supersaturated Al matrix to form small Si particles. With increasing the solution temperature, the size of the Si particles increases, whereas their number decreases. After artificial aging, the Si particles are further coarsened. The variation in size of Si particles has a significant influence on the mechanical properties of the AlSi10Mg samples. The tensile strength decreases from 434.25±10.7 MPa for the as-built samples to 168.11±2.4 MPa, while the fracture strain remarkably increases from 5.3±0.22% to 23.7±0.84% when the as-built sample is solution-treated at 550 °C for 2 h. This study indicates that the microstructure and mechanical properties of SLM-processed AlSi10Mg alloy can be tailored by suitable solution and artificial aging heat treatments.

The microstructure and mechanical properties of selectively laser melted AlSi10Mg: The effect of a conventional T6-like heat treatment

Abstract: Selective laser melting (SLM) of aluminium is of research interest because of its potential benefits to high value manufacturing applications in the aerospace and automotive industries. In order to demonstrate the credibility of SLM Al parts, their mechanical properties need to be studied. In this paper, the nano-, micro-, and macro-scale mechanical properties of SLM AlSi10Mg were examined. In addition, the effect of a conventional T6-like heat treatment was investigated and correlated to the generated microstructure. Nanoindentation showed uniform hardness within the SLM material. Significant spatial variation was observed after heat treatment due to phase transformation. It was found that the SLM material's micro-hardness exceeded its die-cast counterpart. Heat treatment softened the material, reducing micro-hardness from 125±1 HV to 100±1 HV. An ultimate tensile strength (333 MPa), surpassing that of the die cast counterpart was achieved, which was slightly reduced by heat treatment (12%) alongside a significant gain in strain-to-failure (~threefold). Significantly high compressive yield strength was recorded for the as-built material with the ability to withstand high compressive strains. The SLM characteristic microstructure yielded enhanced strength under loading, outperforming cast material. The use of a T6-like heat treatment procedure also modified the properties of the material to yield a potentially attractive compromise between the material's strength and ductility making it more suitable for a wider range of applications and opening up further opportunities for the additive manufacturing process and alloy combination.

State-of-the-art in surface integrity in machining of nickel-based super alloys

Abstract: Nickel-based super alloys are gaining more significance, now-a-days, with extensive applications in aerospace, marine, nuclear reactor and chemical industries. Several characteristics including superior mechanical and chemical properties at elevated temperature, high toughness and ductility, high melting point, excellent resistance to corrosion, thermal shocks, thermal fatigue and erosion are primarily responsible for wide domain of application. Nevertheless, machined surface integrity of nickel-based super alloys is a critical aspect which influences functional performance including fatigue life of the component. This review paper presents state-of-the-art on various surface integrity characteristics during machining of nickel-based super alloys. Influence of various cutting parameters, cutting environment, coating, wear and edge geometry of cutting tools on different features of surface integrity has been critically explained. These characteristics encompass surface roughness, defects (surface cavities, metal debris, plucking, smeared material, redeposited material, cracked carbide particles, feed marks, grooves and laps), metallurgical aspects in the form of surface and sub-surface microstructure phase transformation, dynamic recrystallisation and grain refinement and mechanical characteristics such as work hardening and residual stress. Microstructural modification of deformed layer, profile of residual stresses and their influence on fatigue durability have been given significant emphasis. Future research endeavour might focus on development of new grades, advanced processing techniques of the same to ensure their superior stability of microstructure and thermo-mechanical properties along with advanced manufacturing processes like additive manufacturing to achieve highest level of fatigue durability of safety critical components while maintaining acceptable surface integrity and productivity.

Selective laser melting of high strength Al–Cu–Mg alloys: Processing, microstructure and mechanical properties

Abstract: The interest for a wider range of usable materials for the technology of selective laser melting (SLM) is growing. In this work, the manufacturing of wrought Al–Cu–Mg parts using SLM technology was systematically investigated. The effect of processing parameters on the density of the deposited Al–Cu–Mg samples was studied. It shows that the laser energy density plays a significant role in the densification behavior of the Al–Cu–Mg powder during the SLM process. The laser energy density value of 340 J/mm3 is found to be the threshold, above which high density samples (99.8%) without imperfections and microcracks can be obtained. The SLMed Al–Cu–Mg part presents a unique layer-wise feature which consisted of an extremely fine supersaturated cellular-dendrites structure. The ultimate tensile strength of 402 MPa and the yield strength of 276 MPa are achieved for the SLMed Al–Cu–Mg part. The combination of grain refinement and solid solution strengthening mechanisms during SLM process are proposed to explain the high mechanical strength.

The microstructure, mechanical properties and corrosion resistance of 316 L stainless steel fabricated using laser engineered net shaping

Abstract: The mechanical properties and corrosion resistance of 316 L stainless steel fabricated using the Laser Engineered Net Shaping (LENS) technique have been studied. The crack-free, full density samples made using SS316L alloy powder and the LENS technique are characterized by an unusual distinct dual-phase microstructure. STEM analysis revealed a significant increase of Cr and Mo content and a decrease of Ni in the grain boundaries. Based on the Cr and Ni content (austenite stabilizing elements), the Schaeffler diagram and the EBSD results, the existence of intercellular delta ferrite on subgrain boundaries and austenite in the fine-grains are observed. The XRD patterns, in addition to the FCC austenite phase, revealed the second BCC ferrite phase. Moreover, the sigma (FeCr) phases are present in the analyzed 316 L stainless steel. The occurrence of ferrite, which does not occur in regular stainless steel fabricated using conventional metallurgical methods, improves the mechanical and corrosion properties of the LENS-fabricated sample made using 316 L stainless steel powder. The obtained results prove that the microstructure of the SS316L fabricated using LENS is heterogeneous; its impact on the mechanical properties is visible. The analyzed samples are characterized by anisotropic mechanical properties that are favorable. For both the perpendicular and parallel directions of tensile tests, samples had a ductile fracture with many dimples inside of the larger dimples. The corrosion potential of SS316L LENS and classically manufactured steel is similar. The SS316L fabricated using LENS is characterized by a relatively low value of corrosion current density, which translates into much smaller corrosion rates.

Ultrafine-Grained AlCoCrFeNi2.1 Eutectic High-Entropy Alloy

Abstract: The development of microstructure and mechanical properties was investigated in a heavily cold-rolled and annealed AlCoCrFeNi2.1 high-entropy alloy. The as-cast alloy having a eutectic morphology consisting of alternate bands of ordered L1(2) and B2 phases was 90% cold-rolled. The deformed microstructure showed profuse shear banding and disordering of the L12, but no transformation of the B2 phase. A duplex microstructure consisting of ultrafine equiaxed grains (similar to 0.60 mu m) of disordered face centered cubic and B2 was observed after annealing at 800 degrees C. The annealed material showed remarkable strength-ductility combination having ultimate tensile strength similar to 1.2 GPa and elongation to failure similar to 12%.

Modeling of heat transfer, fluid flow and solidification microstructure of nickel-base superalloy fabricated by laser powder bed fusion

Abstract: Laser-Powder Bed Fusion (L-PBF), an additive manufacturing process, produces a distinctive microstructure that closely resembles the weld metal microstructure but at a much finer scale. The solidification parameters, particularly temperature gradient and solidification rate, are important to study the as-built microstructure. In the present study, a computational framework with meso-scale resolution is developed for L-PBF of Inconel® 718 (IN718), a Ni-base superalloy. The framework combines a powder packing model based on Discrete Element Method and a 3-D transient heat and fluid flow simulation. The latter, i.e., the molten pool model, captures the interaction between laser beam and individual powder particles including free surface evolution, surface tension and evaporation. The solidification parameters, calculated from the temperature fields, are used to assess the solidification morphology and grain size using existing theoretical models. The IN718 coupon built by L-PBF are characterized using optical and scanning electron microscopies. The experimental data of molten pool size and solidification microstructure are compared to the corresponding simulation results.

Electron beam melted Ti–6Al–4V: Microstructure, texture and mechanical behavior of the as-built and heat-treated material

Abstract: Electron Beam Melting (EBM), a powder bed additive layer manufacturing process, was used to produce Ti–6Al–4V specimens, whose microstructure, texture, and tensile properties were fully characterized. The microstructure, analyzed by optical microscopy, SEM/EBSD and X-ray diffraction, consists in fine α lamellae. Numerical reconstruction of the parent β phase highlighted the columnar morphology of the prior β grains, growing along the build direction upon solidification of the melt pool. The presence of grain boundary αGB along the boundaries of these prior β grains is indicative of the diffusive nature of the β→α phase transformation. Texture analysis of the reconstructed high temperature β phase revealed a strong pole in the build direction. For mechanical characterization, tensile specimens were produced using two different build themes and along several build orientations, revealing that vertically built specimens exhibit a lower yield strength than those built horizontally. The effect of post processing, either mechanical or thermal, was extensively investigated. The influence of surface finish on tensile properties was clearly highlighted. Indeed, mechanical polishing induced an increase in ductility – due to the removal of critical surface defects – as well as a significant increase of the apparent yield strength – caused by the removal of a ~150 µm rough surface layer that can be considered as mechanically inefficient and not supporting any tensile load. Thermal post-treatments were performed on electron beam melted specimens, revealing that subtransus treatments induce very moderate microstructural changes, whereas supertransus treatments generate a considerably different type of microstructure, due to the fast β grain growth occurring above the transus. The heat treatments investigated in this work had a relatively moderate impact on the mechanical properties of the parts.

Effects of the microstructure and porosity on properties of Ti-6Al-4V ELI alloy fabricated by electron beam melting (EBM)

Abstract: Electron beam melting (EBM) is a metal powder bed fusion additive manufacturing (AM) technology that makes possible the fabrication of three-dimensional near-net-shaped parts directly from computer models. EBM technology has been continuously evolving, optimizing the properties and the microstructure of the as-fabricated alloys. Ti-6Al-4V ELI (Extra Low Interstitials) titanium alloy is the most widely used and studied alloy for this technology and is the focus of this work. Several research works have been completed to study the mechanisms of microstructure formation, evolution, and its subsequent influence on mechanical properties of the alloy. However, the relationship is not completely understood, and more systematic research work is necessary in order to attain a better understanding of these features. In this work, samples fabricated at different locations, orientations, and distances from the build platform have been characterized, studying the relationship of these variables with the resulting material intrinsic characteristics and properties (surface topography, microstructure, porosity, micro-hardness and static mechanical properties). This study has revealed that porosity is the main factor controlling mechanical properties relative to the other studied variables. Therefore, in future process development, decreasing the porosity should be considered the primary goal in order to improve mechanical properties.

Review of Mechanical Properties of Ti-6Al-4V Made by Laser-Based Additive Manufacturing Using Powder Feedstock

Abstract: Laser-based additive manufacturing (AM) of metals using powder feedstock can be accomplished via two broadly defined technologies: directed energy deposition (DED) and powder bed fusion (PBF). In these processes, metallic powder is delivered to a location and locally melted with a laser heat source. Upon deposition, the material undergoes a rapid cooling and solidification, and as subsequent layers are added to the component, the material within the component is subjected to rapid thermal cycles. In order to adopt AM for the building of structural components, a thorough understanding of the relationships among the complex thermal cycles seen in AM, the unique heterogeneous and anisotropic microstructure, and the mechanical properties must be developed. Researchers have fabricated components by both DED and PBF from the widely used titanium alloy Ti-6Al-4V and studied the resultant microstructure and mechanical properties. This review article discusses the progress to date on investigating the as-deposited and heat-treated microstructures and mechanical properties of Ti-6Al-4V structures made by powder-based laser AM using DED and PBF.

Tailoring nanostructures and mechanical properties of AlCoCrFeNi2.1 eutectic high entropy alloy using thermo-mechanical processing

Abstract: The effect of thermo-mechanical processing on the evolution of microstructure and mechanical properties was investigated in an AlCoCrFeNi2.1 high entropy alloy. For this purpose, the alloy was cold-rolled to 90% reduction in thickness and annealed at temperatures ranging from 800 °C to 1200 °C. The as-cast alloy revealed eutectic lamellar mixture of (Ni, Al) rich but Cr depleted B2 phase and Al-depleted L12 phases, having volume fractions of ~35% and 65%, respectively. Nanosized precipitates enriched in Cr and having disordered BCC structure were found dispersed inside the B2 phase. Cold-rolling resulted in progressive disordering of the L12 phase but the B2 phase maintained the ordered structure. The disordering of the L12 phase was accompanied by the evolution of ultrafine lamellar structure and profuse shear band formation. Annealing of the 90% cold-rolled material at 800 °C resulted in the formation of a duplex microstructure composed of two different phases with equiaxed morphologies, having significant resistance to grain growth up to 1200 °C. The annealed materials showed disordered FCC and precipitate-free B2 phases. This indicated that quenching of the annealed specimens to room temperature was sufficient to prevent the ordering of the L12 phase and the formation of the Cr-rich nano-precipitates which were dissolved in the B2 phase during annealing. Significant improvement in tensile properties compared to the as-cast alloy could be achieved by thermo-mechanical processing. All the specimens annealed at 800 °C to 1200 °C were having good tensile ductility over 10% as well as high tensile strength greater than 1000 MPa. These indicated that the properties of the EHEA could be successfully tailored using thermo-mechanical processing for a wide range of engineering applications.