Laser-Based Directed Energy Deposition (L-DED) Processing of Water Atomized 42CrMo4 Powder
Tóm tắt
This study investigates the viability of utilizing a low-cost steel feedstock powder in the context of laser-based directed energy deposition (DED) processing. Here, water atomized 42CrMo4 (comparable to 4140) ferrous powder was deposited on a AISI 4140 substrate using an Optomec MTS 500-AM controlled atmosphere DED system. A statistical design of experiments (DOE) approach was used to parametrically model the effects of laser power, laser scan speed, hatch spacing, layer thickness and powder feed rate on the density of the deposited product. The direct impact of these variables was assessed as well as their respective interactions. The resultant model was found to be highly significant and maintained a capacity to predict future results. It was then leveraged to identify a set of deposition parameters that produced high quality deposits with near full theoretical density. The effects of pre and post-build heat treatments on the microstructure, microhardness, and residual stress of L-DED deposits were assessed as well.
Tài liệu tham khảo
Zenou, M., Grainger, L., Additive manufacturing of metallic materials, in: Addit. Manuf., Elsevier, 53–103 (2018). https://doi.org/10.1016/B978-0-12-812155-9.00003-7
DebRoy, T., Wei, H.L., Zuback, J.S., Mukherjee, T., Elmer, J.W., Milewski, J.O., Beese, A.M., Wilson-Heid, A., De, A., Zhang, W.: Additive manufacturing of metallic components – Process, structure and properties. Prog. Mater. Sci. 92, 112–224 (2018). https://doi.org/10.1016/j.pmatsci.2017.10.001
Ansari, M., Mohamadizadeh, A., Huang, Y., Paserin, V., Toyserkani, E.: Laser directed energy deposition of water-atomized iron powder: Process optimization and microstructure of single-tracks. Opt. Laser Technol. 112, 485–493 (2019). https://doi.org/10.1016/j.optlastec.2018.11.054
Durejko, T., Aniszewska, J., Ziȩtala, M., Antolak-Dudka, A., Czujko, T., Varin, R.A., Paserin, V.: The application of globular water-atomized iron powders for additive manufacturing by a LENS technique. Materials (Basel). 11, 1–12 (2018). https://doi.org/10.3390/ma11050843
Tobar, M.J., Amado, J.M., Montero, J., Yáñez, A.: A Study on the Effects of the Use of Gas or Water Atomized AISI 316L Steel Powder on the Corrosion Resistance of Laser Deposited Material. Phys. Procedia. 83, 606–612 (2016). https://doi.org/10.1016/J.PHPRO.2016.08.063
Pinkerton, A.J., Li, L.: The behaviour of water- and gas-atomised tool steel powders in coaxial laser freeform fabrication. Thin Solid Films 453–454, 600–605 (2004). https://doi.org/10.1016/j.tsf.2003.11.171
Castro, G., Rodríguez, J., Montealegre, M.A., Arias, J.L., Yañez, A., Panedas, S., Rey, L.: Laser Additive Manufacturing of High Added Value Pieces. Procedia Eng. 132, 102–109 (2015). https://doi.org/10.1016/j.proeng.2015.12.485
Marya, M., Singh, V., Hascoet, J.-Y., Marya, S.: A Metallurgical Investigation of the Direct Energy Deposition Surface Repair of Ferrous Alloys. J. Mater. Eng. Perform. 27, 813–824 (2018). https://doi.org/10.1007/s11665-017-3117-5
Borrego, L.P., Pires, J.T.B., Costa, J.M., Ferreira, J.M.: Mould steels repaired by laser welding. Eng. Fail. Anal. 16, 596–607 (2009). https://doi.org/10.1016/j.engfailanal.2008.02.010
Leino, M., Pekkarinen, J., Risto, S.: The role of laser additive manufacturing methods of metals in repair, refurbishment and remanufacturing - enabling circular economy. Phys. Procedia. 83, 752–760 (2016). https://doi.org/10.1016/j.phpro.2016.08.077
Kattire, P., Paul, S., Singh, R., Yan, W.: Experimental characterization of laser cladding of CPM 9V on H13 tool steel for die repair applications. J. Manuf. Process. 20, 492–499 (2015). https://doi.org/10.1016/j.jmapro.2015.06.018
Zhang, Q., Chen, G., Wu, G., Xiu, Z., Luan, B.: Property characteristics of a AlNp/Al composite fabricated by squeeze casting technology. Mater. Lett. 57, 1453–1458 (2003). https://doi.org/10.1016/S0167-577X(02)01006-6
Leunda, J., Soriano, C., Sanz, C., Navas, V.G.: Laser cladding of vanadium-carbide tool steels for die repair. Phys. Procedia (2011). https://doi.org/10.1016/j.phpro.2011.03.044
Lewis, S.R., Lewis, R., Fletcher, D.I.: Assessment of laser cladding as an option for repairing/enhancing rails. Wear 330–331, 581–591 (2015). https://doi.org/10.1016/J.WEAR.2015.02.027
Da Sun, S., Liu, Q., Brandt, M., Luzin, V., Cottam, R., Janardhana, M., Clark, G.: Effect of laser clad repair on the fatigue behaviour of ultra-high strength AISI 4340 steel. Mater. Sci. Eng. A. 606, 46–57 (2014). https://doi.org/10.1016/j.msea.2014.03.077
Committee, A.I.H., Handbook, A.S.M.: Volume 01 - Properties and selection: Irons, steels, and high-performance alloys. ASM International (1990). https://doi.org/10.1361/asmhba0001003
Kim, H., Liu, Z., Cong, W., Zhang, H.-C.: Tensile Fracture Behavior and Failure Mechanism of Additively-Manufactured AISI 4140 Low Alloy Steel by Laser Engineered Net Shaping. Materials (Basel). 10, 1283 (2017). https://doi.org/10.3390/ma10111283
Castro, G., Rodríguez, J., Montealegre, M.A., Arias, J.L., Yañez, A., Panedas, S., Rey, L.: Laser Additive Manufacturing of High Added Value Pieces. Procedia Eng. (2015). https://doi.org/10.1016/j.proeng.2015.12.485
El Kadiri, H., Wang, L., Horstemeyer, M.F., Yassar, R.S., Berry, J.T., Felicelli, S., Wang, P.T.: Phase transformations in low-alloy steel laser deposits. Mater. Sci. Eng. A. 494, 10–20 (2008). https://doi.org/10.1016/j.msea.2007.12.011
Foroozmehr, E., Kovacevic, R.: Thermokinetic modeling of phase transformation in the laser powder deposition process, Metall. Mater. Trans. A Phys. Metall. Mater. Sci. 40, 1935–1943 (2009). https://doi.org/10.1007/s11661-009-9870-9
Amano, R.S., Rohatgi, P.K.: Laser engineered net shaping process for SAE 4140 low alloy steel. Mater. Sci. Eng. A. 528, 6680–6693 (2011). https://doi.org/10.1016/j.msea.2011.05.036
Park, J.S., Park, J.H., Lee, M.G., Sung, J.H., Cha, K.J., Kim, D.H.: Effect of Energy Input on the Characteristic of AISI H13 and D2 Tool Steels Deposited by a Directed Energy Deposition Process. Metall. Mater. Trans. A Phys. Metall. Mater. Sci. 47, 2529–2535 (2016). https://doi.org/10.1007/s11661-016-3427-5
Metal Powder Industries Federation (MPIF), Method for determination of density of compacted or sintered powder metallurgy (PM) products, Standard 42, in Standard Test Methods for Metal Powders and Powder Metallurgy Products, Published by Metal Powder Industries Federation (MPIF), pp. 75–78. 105 College Road East, Princeton (2016)
Dass, A., Moridi, A.: State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design. Coatings 9, 418 (2019). https://doi.org/10.3390/coatings9070418
Debroy, T., David, S.A.: Physical processes in fusion welding. Rev. Mod. Phys. 67, 85–112 (1995). https://doi.org/10.1103/RevModPhys.67.85
Mukherjee, T., Zuback, J.S., De, A., DebRoy, T.: Printability of alloys for additive manufacturing. Sci. Rep. 6, 1–8 (2016). https://doi.org/10.1038/srep19717
Wendel, J., Shvab, R., Cao, Y., Hryha, E., Nyborg, L.: Surface analysis of fine water-atomized iron powder and sintered material. Surf. Interface Anal. 50, 1065–1071 (2018). https://doi.org/10.1002/sia.6455
Yamasaki, M., Kawamura, Y.: Changes in the surface characteristics of gas-atomized pure aluminum powder during vacuum degassing. Mater. Trans. 47, 1902–1905 (2006). https://doi.org/10.2320/matertrans.47.1902