Search Results (56)

The escalating demands of industrial applications, particularly those involving severe wear, temperature, and corrosive environments, present significant challenges for the long-term strength of critical components, often fabricated from high-value materials such as super duplex stainless steel alloys. Super duplex can withstand the corrosive environment (in particular, crevice corrosion and pitting damage) and maintain mechanical integrity sufficient for high-pressure pumping applications such as seawater injection and crude oil. Conventional repair methodologies frequently result in component rejection due to process-induced distortions or detrimental phase transformations, contributing to substantial material waste and hindering the adoption of circular economy principles. This research addresses this issue by developing and validating a novel repair process utilizing laser metal deposition (LMD) additive manufacturing. The research focuses on establishing optimized process parameters to ensure the salvaging and restoration of damaged super duplex components while preserving their requisite mechanical integrity and corrosion resistance, in accordance with industry standards. Comprehensive characterization, including microstructural analysis, chemical composition verification, hardness profiling, and mechanical fatigue testing, confirms the efficacy of the LMD repair process. This work demonstrates the potential for extending the service life of critical components, thereby promoting resource efficiency and contributing to a more sustainable and resilient industrial paradigm. Full article

Compared with powder metallurgy, centrifugal casting, jet molding, and other technologies, Laser Melting Deposition (LMD) stands out as an advanced additive manufacturing technology that provides substantial advantages in the melt forming of functional gradient materials and composites. However, when high-temperature and high-speed laser energy is applied, the resulting materials are susceptible to porosity, which restricts their extensive use in fatigue-sensitive applications such as turbine engine blades, engine connecting rods, gears, and suspension system components. Since fatigue cracks generally originate near pore defects or at stress concentration points, it is crucial to investigate evaluation methods for pore defects and stress concentration in LMD applications. This study examines the effect of pore defects on stress concentration in LMD-manufactured AlSi10Mg using the crystal plasticity finite element method and proposes a stress concentration coefficient characterization approach that considers pore size, morphology, and location. The simulation results indicate a competitive mechanism between pores and grains, where the larger entity dominates. Regarding the influence of aspect ratio on stress concentration, as the aspect ratio decreases along the stress direction, the stress concentration increases significantly. When pores are just emerging from the surface (s/r = 1), the stress concentration caused by the pore reaches its maximum, posing the highest risk of material failure. To assess the extent to which the aspect ratio, position, and size of pores affect stress concentration, a statistical correlation analysis of these variables was conducted. Full article

This study explores the fabrication of an equimolar CoCrFeNi high-entropy alloy (HEA) using laser metal deposition (LMD) technique on a 316 L austenitic stainless steel substrate, without pre-alloying. Elemental metal powders were mixed in a planetary ball mill and directly deposited to investigate the effect of layer number on alloy composition and substrate intermixing. Experimental results revealed significant dilution in the first four layers, with substrate intermixing affecting composition. The coarse-grained crystal structure observed in the initial layers persisted in subsequent layers, and hardness measurements indicated the cumulative thermal effects of sequential deposition. From an industrial perspective, this approach offers a cost-effective and flexible manufacturing strategy, eliminating the need for pre-alloying. Moreover, gradient compositional layers can be achieved, enabling tailored material properties. This work demonstrates the feasibility of producing multi-layer HEAs directly from elemental powders while addressing the challenges of compositional stability. Full article

This study explores the fatigue behavior and fracture mechanisms of TC11 titanium alloy formed by laser metal deposition (LMD) and subjected to double annealing. The research focuses on how the alloy’s unique microstructure, consisting of alternating equiaxed and columnar crystals, influences its fatigue performance. The microstructure’s basket-like α’ phase, made up of both plate-shaped and needle-like structures, leads to variations in crack growth behavior, as shown in the relationship between the crack growth rate and the stress intensity. An analysis of slip patterns reveals that equiaxed crystals undergo more frequent deformation, accelerating crack propagation compared to the more evenly distributed deformation in columnar crystals. These findings suggest a new approach for improving the fatigue resistance of 3D-printed titanium alloys by optimizing their microstructure. This study provides valuable insights for enhancing material toughness and extending the lifespan of titanium alloys in applications such as aerospace and biomedical engineering. Full article

The optimization of process parameters in powder Directed Energy Deposition (DED) is essential for achieving consistent, high-quality bead geometries, which directly influence the performance and structural integrity of fabricated components. As a subset of additive manufacturing (AM), the DED process, also referred to as laser metal deposition (LMD), enables precise, layer-by-layer material deposition, making it highly suitable for complex geometries and part repair applications. Critical parameters, such as the laser power, feed rate, powder mass flow, and substrate temperature govern the deposition process, impacting the bead height, width, contact angle, and dilution. Inconsistent control over these variables can lead to defects, such as poor bonding, dimensional inaccuracies, and material weaknesses, ultimately compromising the final product. This paper investigates the effects of various process parameters, specifically the substrate temperature, on bead track geometry in DED processes for stainless steel (1.4404). A specialized experimental setup, integrated within a DED machine, facilitates the controlled thermal conditioning of sample sheets. Using Design of Experiments (DoE) methods, individual bead marks are generated and analyzed to assess geometric characteristics. Regression models, including both linear and quadratic approaches, are constructed to predict machine parameters for achieving the desired bead geometry at different substrate temperatures. Validation experiments confirm the accuracy and reliability of the models, particularly in predicting the bead height, bead width, and contact angle across a broad range of substrate temperatures. However, the models demonstrated limitations in accurately predicting dilution, indicating the need for further refinement. Despite some deviations in measured values, successful fabrication is achieved, demonstrating robust bonding between the bead and substrate. The developed models offer insights into optimizing DED process parameters to achieve desired bead characteristics, advancing the precision and reliability of additive manufacturing technology. Future work will focus on refining the regression models to improve predictions, particularly for dilution, and further investigate non-linear interactions between process variables. Full article

New developments in nickel-based superalloys and production methods, such as the use of additive manufacturing (AM), can result in innovative designs for turbines. It is crucial to understand how the material behaves during the AM process to advance the industrial use of these techniques. An analytical model based on reaction–diffusion formalism is developed to better explain the solidification behavior of the material during laser metal deposition (LMD). The well-known Scheil–Gulliver theory has some drawbacks, such as the assumption of equilibrium at the solid–liquid interface, which is addressed by this method. The solidified fractions under the Scheil model and the pure equilibrium model are calculated using CALPHAD simulations. A differential scanning calorimeter is used to measure the heat flow during the solid–liquid phase transformation, the result of which is further converted to solidified fractions. The analytical model is compared with all the other models for validation. Full article

CoCrFeNi HEAs have better ductility, while the strength and corrosion resistance need to be further improved, while metal materials for deep-sea operations put forward the requirement of excellent mechanical properties and very high corrosion resistance; however, CoCrFeNi HEAs have been less studied for the trade-off between mechanical properties and corrosion resistance. Therefore, the present study utilized the laser melting deposition (LMD) technique to fabricate a series of (CoCrFeNi)Ti_x (x = 0.2, 0.4, 0.6, 0.8, 1.0 at.%) HEAs and systematically investigated the influence of Ti content on the alloy’s microstructure, phase composition, mechanical properties, and electrochemical performance. The research findings revealed that as the Ti content increased, the alloy gradually transformed from a single face-centered cubic (FCC) phase to an FCC and body-centered cubic (BCC) dual-phase structure. The addition of Ti induced a transition in the alloy’s microstructure from an equiaxed to a dendritic morphology, accompanied by grain refinement. Energy dispersive spectroscopy analysis confirmed the uniform distribution of Ti within the alloy. The hardness of the alloy increased significantly with the increase in Ti content, reaching 804.5 HV when the Ti content was 1.0 at.%, which was 4.13 times higher than the Ti-free alloy. The tensile and compression test results showed that the (CoCrFeNi)Ti_x alloy with a Ti content of 0.4 at.% exhibited the best overall mechanical performance. The electrochemical test results indicated that the addition of Ti effectively enhanced the corrosion resistance of the alloy, with the 0.4 at.% Ti-containing alloy exhibiting the optimal corrosion resistance. This study provides a strong theoretical and experimental foundation for the design of high-performance CoCrFeNi-based HEAs. Full article

High-entropy alloys (HEAs) are recognized as a class of advanced materials with outstanding mechanical properties and corrosion resistance. Among these, nickel-based HEAs stand out for their impressive strength, ductility, and oxidation resistance. This review delves into the latest advancements in nickel-containing HEAs, covering their fundamental principles, alloy design strategies, and additive manufacturing techniques. We start by introducing HEAs and their unique properties, emphasizing the crucial role of nickel. This review examines the complex relationships between alloy composition, valence electron concentration (VEC), and the resulting crystal structures. This provides insights into design principles for achieving desired microstructures and mechanical properties. Additive manufacturing (AM) techniques like selective laser melting (SLM), electron beam melting (EBM), and laser metal deposition (LMD) are highlighted as powerful methods for fabricating intricate HEA components. The review addresses the challenges of AM processes, such as porosity, fusion defects, and anisotropic mechanical properties, and discusses strategies to mitigate these issues through process optimization and improved powder quality. The mechanical behavior of AM-processed nickel-based HEAs is thoroughly analyzed, focusing on compressive strength, hardness, and ductility. This review underscores the importance of microstructural features, including grain size, phase composition, and deformation mechanisms, in determining the mechanical performance of these alloys. Additionally, the influence of post-processing techniques, such as heat treatment and hot isostatic pressing (HIP) on enhancing mechanical properties is explored. This review also examines the oxidation behavior of nickel-containing HEAs, particularly the formation of protective oxide scales and their dependence on aluminum content. The interplay between composition, VEC, and oxidation resistance is discussed, offering valuable insights for designing corrosion resistant HEAs. Finally, this review outlines the potential applications of nickel-based HEAs in industries such as aerospace, automotive, and energy, and identifies future research directions to address challenges and fully realize the potential of these advanced materials. Full article

HfNbTaTiZr high-entropy alloy has wide application prospects as a biomedical material, and the use of laser additive manufacturing can solve the forming problems faced by the alloy. In view of the characteristics of the one-time forming of additive manufacturing methods, it is necessary to develop non-mechanical processing modification methods. In this paper, deep cryogenic treatment (DCT) is first applied to the modification of a HEA with BCC structure, then the post-processing method of DCT is combined with laser melting deposition (LMD) technology to successfully realize the coordinated improvement of forming and strength–ductility synergistic improvement in lightweight Hf_0.25NbTa_0.25TiZr alloy. The final tensile strength of the alloy after DCT treatment is 25% higher than that of the as-cast alloy and 11% higher than that of the as-deposited alloy, and the elongation is increased by 48% and 10%, respectively. In addition, DCT also achieves induced phase transition without additional deformation. Full article

Additive manufacturing (AM) technologies enable near-net-shape designs and demand-oriented material usage, which significantly minimizes waste. This points to a substantial opportunity for further optimization in material savings and process design. The current study delves into the advancement of sustainable manufacturing practices in the automotive industry, emphasizing the crucial role of lightweight construction concepts and AM technologies in enhancing resource efficiency and reducing greenhouse gas emissions. By exploring the integration of novel AM techniques such as selective laser melting (SLM) and laser metal deposition (LMD), the study aims to overcome existing limitations like slow build-up rates and limited component resolution. The study’s core objective revolves around the development and validation of a continuous process chain that synergizes different AM routes. In the current study, the continuous process chain for DMG MORI Lasertec 65 3D’s LMD system and the DMG MORI Lasertec 30 3D’s was demonstrated using 316L and 1.2709 steel materials. This integrated approach is designed to significantly curtail process times and minimize component costs, thus suggesting an industry-oriented process chain for future manufacturing paradigms. Additionally, the research investigates the production and material behavior of components under varying manufacturing processes, material combinations, and boundary layer materials. The culmination of this study is the validation of the proposed process route through a technology demonstrator, assessing its scalability and setting a benchmark for resource-efficient manufacturing in the automotive sector. Full article

The titanium alloy components utilized in the aviation field are typically large in size and possess complex structures. By utilizing multiple additive manufacturing processes, the precision and efficiency requirements of production can be met. We investigated the hybrid additive manufacturing of Ti-6Al-4V using a combination of cold metal transfer additive manufacturing (CMTAM) and laser metal deposition (LMD), as well as the feasibility of using the CMT-LMD hybrid additive manufacturing process for fabricating Ti-6Al-4V components. Microstructural examinations, tensile testing coupled with digital image correlation and dynamic compressive experiments (by the split Hopkinson pressure bar (SHPB) system) were employed to assess the parts. The results indicate that the interface of the LMD and CMTAM zone formed a compact metallurgical bonding. In the CMTAM and LMD zone, the prior-β grains exhibit epitaxial growth, forming columnar prior-β grains. Due to laser remelting, the CMT-LMD hybrid additive zone experiences grain refinement, resulting in equiaxed prior-β grains at the interface with an average grain size smaller than that of the CMTAM and LMD regions. The microstructures reveal significant differences in grain orientation and morphology among the zones, with distinct textures forming in each zone. In the CMT-LMD hybrid zone, due to interfacial strengthening, strain concentration occurs in the arc additive zone during tensile testing, leading to fracture on the CMTAM zone. Under high-strain-rate dynamic impact conditions, the LMD region exhibits ductile fracture, while the CMTAM zone demonstrates brittle fracture. The hybrid zone combines ductile and brittle fracture modes, and the CMT-LMD hybrid material exhibits superior dynamic impact performance compared to the single deposition zone. Full article

The long, straight grain boundary of the high-entropy alloy (HEA) produced via laser melting deposition (LMD) is prone to cracking due to unidirectional scanning (single wall). To enhance the competitive growth of columnar grains and improve the overall performance of the alloy, a vertical cross scanning method was employed to fabricate FeCoCrNi HEA (bulk). The influence of grain orientation on the microstructure and mechanical properties of FeCoCrNi-LMD was systematically investigated. Microhardness tests and tensile tests were conducted to assess the mechanical property differences between the single-wall and bulk samples. This study shows that using a single scanning strategy results in monolayer wall grains sized at 129.40 μm, with a max texture strength of 21.29. Employing orthogonal scanning yields 61.15 μm block-like grains with a max texture strength of 11.12. Dislocation densities are 1.084 × 10¹² m⁻² and 1.156 × 10¹² m⁻², with average Schmid factors of 0.471 and 0.416. In comparison to the FeCoCrNi-LMD single wall, the bulk material produced through cross-layer orthogonal scanning exhibited reduced residual stress, weakened anisotropy, and improved mechanical properties. These findings are expected to enhance the potential applications of FeCoCrNi-LMD in various industries. Full article

Gray cast iron (GJL) is known for its excellent damping property and high thermal conductivity, thanks to its unique lamellar graphite and pearlite structure. In a recent study, laser metal deposition (LMD) was explored as a potential process to enhance the corrosion resistance and wear mechanism of this tribological system. The focus was on laser cladding of gray cast iron using two different of stainless-steel materials, namely 430L and 316L, combined with TiC and WC particles. To create the samples, a multilayer coating system was employed. A comparative analysis of the microstructures was performed to understand the interaction of the laser beam with the material (composite materials). Surface properties were then characterized using light microscopy and electron microscopy (SEM) before and after subjecting the samples to a shock corrosion test, simulating automotive conditions. Additionally, phase analyses were performed at the interfaces between the coatings and the substrate, with particular attention given to the behavior of the graphite lamellae at these interfaces. This study aims to provide valuable insights into the potential improvements that can be achieved through laser cladding on gray cast iron, specifically in terms of corrosion resistance and wear mechanisms. By analyzing the microstructures and surface properties, researchers can gain a better understanding of the performance and durability of the coated samples. Full article

Additive Manufacturing (AM) of the Ti–6Al–4V alloy has gained significant importance across various industries, including biomedical, aerospace, cellular, and land vehicle applications, due to its numerous benefits. The certification of performance and reliability of AM materials, particularly for critical applications, heavily relies on evaluating fatigue strength. In this study, a numerical analysis based on the finite element method is presented to predict the High Cycle Fatigue (HCF) behavior of AM Ti–6Al–4V alloy. The investigation focuses on exploring the sensitivity of material fatigue life to surface roughness and Ultimate Tensile Strength (UTS). Uniaxial tensile and High Cycle Fatigue (HCF) tests were conducted on Ti–6Al–4V alloy samples extracted from rectangular walls manufactured using the Laser Metal Deposition (LMD) process. The walls were surface machined prior to sample extraction. Porosity and surface roughness measurements were performed on the samples. Numerical simulations of the HCF tests were carried out, considering various surface roughness ranges and UTS values. The numerical results were then compared to experimental data. The findings consistently demonstrated that higher surface roughness led to a shorter fatigue life, while higher UTS values resulted in a longer fatigue life. The numerical solutions aligned with the experimental results, indicating the efficacy of the finite element method in predicting the fatigue behavior of AM Ti–6Al–4V alloy. These insights contribute to a better understanding of the relationship between surface roughness, UTS, and fatigue life of Ti–6Al–4V alloys manufactured by AM. Full article

Nickel-based Ni-Cr-Si-B self-fluxing alloys are excellent candidates to replace cobalt-based alloys in aeronautical components. In this work, metal additive manufacturing by directed energy deposition using a laser beam (DED-LB, also known as LMD) and gas-atomized powders as a material feedstock is presented as a potential manufacturing route for the complex processing of these alloys. This research deals with the advanced material characterization of these alloys obtained by LMD and the study and understanding of their solidification paths and strengthening mechanisms. The as-built microstructure, the Vickers hardness at room temperature and at high temperatures, the nanoindentation hardness and elastic modulus of the main phases and precipitates, and the strengthening mechanisms were studied in bulk cylinders manufactured under different chemical composition grades and DED-LB/p process parameter sets (slow, normal, and fast deposition speeds), with the aim of determining the influence of the chemical composition in commercial Ni-Cr-Si-Fe-B alloys. The hardening of Ni-Cr-Si-Fe-B alloys obtained by LMD is a combination of the solid solution hardening of gamma nickel dendrites and eutectics and the contribution of the precipitation hardening of small chromium-rich carbides and hard borides evenly distributed in the as-built microstructure. Full article