Advanced Manufacturing of Novel Metallic Related Materials

Silicon carbide (SiC) possesses a unique combination of properties such as high mechanical strength at elevated temperatures, wear resistance, low thermal expansion coefficient, high temperature oxidation resistance, corrosion stability, radiation hardness, high chemical inertness, and thermal conductivity. Unfortunately, SiC is very brittle and cannot, therefore, be used “as is”. SiC’s crack resistance, due to the prevention of crack propagation, can be increased by the reinforcing of SiC. In this paper, a novel method for manufacturing SiC-based composites reinforced with Mo wire is developed. The composites are produced by infiltrating porous carbon blanks with molten silicon. The molten silicon reacts with the molybdenum wire embedded in the carbon blanks. As a result, a complex interfacial silicide layer with a predominant MoSi₂ phase is formed on the surface of the Mo wire. In addition, a thin layer of Mo₅Si₃ is formed between the residual metal in the core of the wire and the disilicide. A stable bond of the interfacial layer with both the residual metal and the SiC-based ceramic matrix is observed. Mechanical tests on the obtained samples for three-point bending at 20 and 1500 °C showed quasi-plastic damage. The reinforcing elements act as stoppers for propagating cracks in the event of a matrix failure. The developed method for producing composites with a ceramic matrix reinforced with metal wire makes it possible to reduce the cost of machining and manufacturing products with complex geometric shapes. It also opens the way for broader applications of SiC-based composites. Full article

In the presented research work, 3D materials were fabricated by additive moulding by means of extrusion of a mixture of high filled polymers and nanopowders of Ti-Al intermetallides with subsequent sintering at 1100 ± 20 °C, 1200 ± 20 °C and 1250 ± 20 °C (MEAM-HP process). Nanopowders of Ti-Al intermetallides were obtained by the electrical explosion of intertwined aluminium and titanium wires. It was found that the structure of the materials comprises an AlTi matrix with Ti₂AlN MAX-phase particles distributed within it, surrounded by a composite layer of Ti₃Al-Ti₂AlN. Sintering temperature increases led to changes in the concentration of TiAl, Ti₃Al and Ti₂AlN phases in the samples. Besides that, aluminium oxide particles were discovered in the structure of the materials. It was found that as the sintering temperature was increased from 1100 ± 20 °C to 1250 ± 20 °C, the average microhardness of the samples increased from 193 to 690 HV_0.1. Full article

One of the issues that modern implants face is their high stiffness, coupled with a positive Poisson’s ratio along the implant. This creates certain problems with bone inflammation and implant detachment. A possible solution to these problems is TiNi alloy lattice structure implants with low stiffness and negative Poisson’s ratio. This paper presents the results of simulation, fabrication by the SLM technique, and study of lattice structures with negative Poisson’s ratio, which can help to solve said problems. The studies involve the determination of mechanical characteristics, Poisson’s ratio, transformation temperatures, and the potential for a superelasticity effect of the lattice structure. The characteristics obtained at initial simulation were partially confirmed in the course of the works. Moreover, the possibility of fabricating TiNi alloy lattice structures with negative Poisson’s ratio (about −0.00323) and low Young’s modulus values (0.818 GPa) was confirmed by the SLM technique. Full article

Market demands coating processes with high-performance, high reliability, high flexibility for processing of complex geometries and multi-material depositions, as well as increased deposition rates. The systematic coupling of two plasma transferred arc welding systems that interact in the same melt pool to form a tandem Plasma Transferred Arc (PTA) system accomplishes these tasks. Previous research has shown that the deposition rate with the tandem PTA method reaches 240 percent when comparing to the conventional single torch PTA method. Within one layer, up to four different powders and powder fractions can be combined at the same time. This allows for the creation of multi-material coatings that are suitable for sustaining high mechanical loads and wear- and temperature-resistant surfaces by use of tungsten carbides (WC). This study examines and analyzes defined functionally graded structures made from super duplex steel 1.4410 and corrosion resistant austenitic steel 1.4404. The mechanical-chemical properties of the tandem PTA system can be precisely controlled by changing the powder feeding positions. Furthermore, an additively manufactured specimen from previous studies is examined and evaluated. A direct comparison with conventional single torch PTA was performed to demonstrate the benefits of the tandem PTA-process. Full article

In this work, Ti-22Al-23Nb-0.8Mo-0.3Si-0.4C-0.1B-0.2Y (at. %) alloy powder was used to fabricate the Ti₂AlNb-based alloy samples using Laser powder bed fusion (L-PBF) Additive Manufacturing with a high-temperature substrate preheating. L-PBF process parameters, including laser power, scan speed, hatching distance, and preheating temperature, allowing for obtaining fully dense (99.9% relative density) crack-free samples, were determined. The effects of substrate preheating temperature during the L-PBF process on microstructure, phase composition, and properties of the obtained Ti₂AlNb-based alloy were investigated using X-ray diffraction, scanning electron microscopy, electron backscatter diffraction analysis, and microhardness testing. The results obtained for the material with C, B, and Y microalloying were compared to the Ti₂AlNb-based alloy fabricated by L-PBF from the powder not alloyed with C, B, and Y. The results revealed that the microalloying reduced the number of solidification cracks; however, no significant microstructural changes were observed, and high-temperature substrate preheating was still necessary to suppress cold cracking of the alloy. The microstructure of the alloy varied from fully-β/B2, B2 + O, to fully-O depending on the preheating temperature. Effects of hot isostatic pressing and heat treatment conditions on microstructure and mechanical properties were investigated. Full article

In this work, MIG process was utilized for the wire arc additive manufacturing of the wall-shaped parts, using NiTi shape-memory alloy. High-scale specimens consisting of 20 layers were deposited by using Ni-rich (Ni55.56Ti wt.%) wire as a feedstock on the NiTi substrate with the identical chemical composition. One of two specimens was heat-treated at a temperature of 430 °C for 1 h. The influence of such a heat treatment on the microstructure, phase transformation temperatures, chemical and phase compositions, microhardness, and tensile and bending tests’ results is discussed. As-deposited metal successfully demonstrates superelastic behavior, except in the lower zone. In regard to the shape-memory effect, it was concluded that both the as-deposited and the heat-treated samples deformed in liquid nitrogen completely restored (100%) their shapes at an initial strain of 4–5%. An occurrence of the R-phase was found in both the as-deposited and the heat-treated specimens. The phase transformation temperatures, microstructure, and tensile and bending tests results were found to be anisotropic along the height of the specimens. The presented heat treatment led to changes in the functional and mechanical properties of the specimen, provided with the formation of finely dispersed Ni4Ti3, NiTi2, and Ni3Ti phases. Full article

Advanced aluminides strengthened with incoherent Laves phase precipitates are promising lightweight and creep-resistant alternatives for high-alloy steels and superalloys for high-temperature critical components up to 750 °C service temperature. A significant issue with manufacturing these aluminides with conventional casting is the strong coarsening tendency of the Laves phase precipitates at elevated temperatures, leading to a significant strength reduction. In this context, the short lifetime of the melt pool in additive manufacturing and its fast solidification and cooling rates promise to consolidate these aluminides with homogeneously distributed fine Laves phase particles without coarsening. The main scientific objective of this work is to exploit the unique characteristics of the laser powder bed fusion (L-PBF) additive manufacturing (AM) process to print dense and crack-free bulk Fe₃Al-1.5Ta samples containing uniformly distributed (Fe, Al)₂Ta Laves phase precipitates. The Fe-25Al-2Ta (at.%) alloy was selected for this work since its creep resistance at 650 °C surpasses the one of the P92 martensitic–ferritic steel (one of the most creep-resistant alloys developed for steam turbine applications). Fundamentals on process–microstructure relationships governing the L-PBF-fabricated builds are provided by a detailed microstructural characterization using X-ray diffractometer (XRD) and ultra-high-resolution scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDX) and high-resolution electron backscatter diffraction (EBSD) detectors. Orientation imaging microscopy (OIM) and grain reference orientation deviation (GROD) maps were applied to measure texture and visualize substructures within the grains. The mechanism of voids formation, morphology, and volume fraction as a function of the input energy density was identified. The melting and solidification dynamics led to microstructures with large columnar grains, porosity, and periodic cracks during the printing process. Processing samples at the building temperatures below the brittle-to-ductile transition temperature, BDTT (750 °C), often caused severe macrocracking and delamination. Crack-free samples with densities higher than 99%, some approaching 99.5%, were fabricated from pre-alloyed gas-atomized powders with a combination of high laser power (250–300 W), slow-to-medium scanning speed (500–1000 mm/s), and 800 °C build plate preheating using a 67° rotation scanning strategy. The morphology of the pores in the volume of the samples indicated a relatively sharp transition from spherical geometry for scanning speeds up to 1000 mm/s to crack-like pores for higher values. The ultra-fast cooling during the L-PBF process suppressed D0₃ Fe₃Al-ordering. The Fe₃Al-1.5Ta builds were characterized by B2 FeAl-type order clusters dispersed within a disordered A2 α-(Fe, Al) matrix. Additionally, the (Fe, Al)₂Ta Laves phase (C14–P6₃/mmc) was predominantly formed at the matrix phase grain boundaries and frequently dispersed within the grains. The quantitative EDX analysis of the matrix gave 77.6–77.9 at.% Fe, 21.4–21.7 at.% Al, and 0.6–0.8 at.% Ta, while the composition of the Laves phase was 66.3–67.8 at.% Fe, 8.7–9.8 at.% Al, and 22.4–24.9 at.% Ta, indicating that the Laves phase is considerably enriched in Ta with respect to the matrix. The L-PBF-fabricated alloys were characterized by coarse, columnar grains which grow epitaxially from the substrate, were several m in width, and extended across several layers along the building direction. The grains exhibited a relatively strong microtexture close to <0 0 1> with respect to the building direction. The L-PBF builds showed a bulk hardness value comparable to the as-cast and spark plasma-sintered counterparts. A negligible variation of the hardness across the build height was observed. Within the framework of this study, we demonstrated that the porosity and cracking issues could be resolved mainly by controlling the process parameters and preheating the build platform above the BDTT. Nevertheless, alloy modifications and/or post-manufacturing processing are required for microstructure refinement. Full article

Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The influence of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. More compressive stresses are induced in the tool as the cross-section of the weld bead is increased. Furthermore, keeping a gap between the adjacent beads improves tool reinforcement. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters. Full article

In this study, the influence of laser polishing on the microstructural and mechanical properties of additively manufactured aluminium AlSi10Mg Laser Powder Bed Fusion (L-PBF) parts is analysed. The investigation is carried out on a 5-axis laser cell equipped with 1D Scanner optics driven by a solid-state disc laser at a wavelength of 1030 nm. Laser polishing is performed with pulsed or continuous laser radiation on samples in the initial L-PBF state or after stress relief treatment in a furnace. The metallurgical investigation of the remelting zone with a depth of 101–237 µm revealed an unchanged and homogeneous chemical composition, with a coarsened α-phase and a changed grain structure. The hardness within the remelting zone is reduced to 102–104 HV 0.1 compared to 146 HV 0.1 at the L-PBF initial state. Below the remelting zone, within the heat affected zone, a reduced microhardness, which can reach a thickness up to 1.5 mm, occurs. Laser polishing results in a reduction in residual stresses and resulting distortions compared to the L-PBF initial state. Nevertheless, the re-solidification shrinkage of the polished surface layer introduces additional tensions, resulting in sample distortions well above ones remaining after a stress relieve heat treatment of the initial state. The mechanical properties, analysed on laser polished flat tensile specimens, revealed an increase in the ultimate elongation from 4.5% to 5.4–10.7% and a reduction in the tensile strength from 346 N/mm² to 247–271 N/mm² through laser polishing. Hence, the strength resulting from this is comparable to the initial L-PBF specimens after stress relieve heat treatment. Full article

The FeCoNiCrMo_0.5Al_x system with x up to 2.13 was analyzed from the point of view of evolution of the phase composition and microstructure. Cast samples were synthesized by induction melting and analyzed by X-ray diffraction, energy dispersive spectroscopy, scanning electron microscopy, and Vickers microhardness test methods. Phase compositions of these alloys in dependance on Al concentration consist of FCC solid solution, σ-phase, NiAl-based B2 phase, and BCC solid solution enriched with Mo and Cr. Phase formation principles were studied. Al dissolves in a FeCoNiCrMo_0.5 FCC solid solution up to 8 at.%.; at higher concentrations, Al attracts Ni, removing it from FCC solid solution and forming the B2 phase. Despite Al not participating in σ-phase formation, an increase in Al concentration to about 20 at.% leads to a growth in the σ-phase fraction. The increase in the σ-phase was caused by an increase in the amount of B2 because the solubility of σ-forming Mo and Cr in B2 was less than that in the FCC solution. A further increase in Al concentration led to an excess of Mo and Cr in the solution, which formed a disordered BCC solid solution. The hardness of the alloys attained the maximum of 630 HV at 22 and 32 at.% Al. Full article

In this work a study of the selective laser melting process of two NiTi alloys of equiatomic, and rich Ni composition were conducted. A study of the influence of the technological parameters on the alloy density was carried out. Values of technological parameters were obtained to ensure production of samples with the lowest number of defects. When using process parameters with the same energy density but different values of the constituent technological parameters, the amount of nickel carried away by evaporation changed insignificantly. An increase in the energy density led to an increase in the amount of nickel carried away, causing final samples with lower Ni content. When using multiple laser processing in the low-energy parameter set, it was possible to achieve a decrease in the nickel content in the alloy, similar to that with single high-energy processing. DSC studies showed a significant increase in transformation temperatures upon repeated laser processing due to the higher evaporation of nickel. The use of double laser treatment gave a decrease in the final density of the sample compared to a single treatment, but its value is still higher than when using a single treatment with a higher energy density. Full article