Thermodynamics-guided alloy and process design for additive manufacturing

Multicomponent alloys designed to sinter

Powder sintering is a low-energy, net-shape processing route for many new products in the additive manufacturing space. We advance the viewpoint that for future manufacturing, alloys should be designed from materials science principles to sinter quickly at lower temperatures and with controlled final microstructures. Specifically, we illustrate the computational design of multinary Ni-base alloys, whose chemistries permit a low-temperature solid-state sintering scheme without any pressure- or field-assistance, as well as heat-treatability after sintering. The strategy is based on sequential phase evolutions designed to occur during sintering. The reactions involve rapid reorganization of matter to full density in cycles up to just 1200 °C, while conventional Ni alloys sintered in the solid-state require about ten times longer, or more than 250 °C degrees higher temperature. Our approach yields an alloy that benefits from precipitation hardening, has an increased strength ~ 50% higher than solid-state processed commercial Ni alloys, and yet exhibits extensive plasticity beyond 35% uniaxial strain. The results point to a generalizable design scheme for many other alloys designed for solid-state powder processing that can enable greater value from additive manufacturing.

The Role of Dislocation Type in the Thermal Stability of Cellular Structures in Additively Manufactured Austenitic Stainless Steel

The ultrafine cellular structure promotes the extraordinary mechanical performance of metals manufactured by laser powder-bed-fusion (L-PBF). An in-depth understanding of the mechanisms governing the thermal stability of such structures is crucial for designing reliable L-PBF components for high-temperature applications. Here, characterizations and 3D discrete dislocation dynamics simulations are performed to comprehensively understand the evolution of cellular structures in 316L stainless steel during annealing. The dominance of screw-type dislocation dipoles in the dislocation cells is reported. However, the majority of dislocations in sub-grain boundaries (SGBs) are geometrically necessary dislocations (GNDs) with varying types. The disparity in dislocation types can be attributed to the variation in local stacking fault energy (SFE) arising from chemical heterogeneity. The presence of screw-type dislocations facilitates the unpinning of dislocations from dislocation cells/SGBs, resulting in a high dislocation mobility. In contrast, the migration of SGBs with dominating edge-type GNDs requires collaborative motion of dislocations, leading to a sluggish migration rate and an enhanced thermal stability. This work emphasizes the significant role of dislocation type in the thermal stability of cellular structures. Furthermore, it sheds light on how to locally tune dislocation structures with desired dislocation types by adjusting local chemistry-dependent SFE and heat treatment.

Fracture behavior of additively manufactured corrax maraging stainless steel

Additively manufactured a low carbon Fe-Cr-Ni-Al Corrax stainless steel has ultra-high strength, but the mechanism at work when the steel cracks is still unclear. In this study, Corrax stainless steel was tensile tested to fracture and cracks in the vicinity of the fracture surface were analyzed by scanning electron microscope and electron-backscattered diffraction. The results show that the cracks propagated at angles of 45-60° to the tensile axis. Some cracks were transgranular, and high-angle grain boundaries had little effect on crack propagation. Crack propagation was inhibited in regions with lower Taylor factors. Kernel average misorientation value analysis established that the crack propagation process is accompanied by significant plastic deformation. The influence of particles and unfused pores on crack propagation is also discussed.

Review on Fatigue of Additive Manufactured Metallic Alloys: Microstructure, Performance, Enhancement, and Assessment Methods

Additive manufacturing (AM), which is a process of building objects in a layer-upon-layer fashion from designed models, has received unprecedented attention from research and industry because it offers outstanding merits of flexibility, customization, reduced buy-to-fly ratio, and cost-effectiveness. However, the fatigue performance of safety-critical industrial components fabricated by AM is still far below that obtained from conventional methods. This review discusses the microstructural heterogeneities, randomly dispersed defects, poor surface quality, and complex residual stress generated during the AM process that can negatively impact the fatigue performance of as-printed parts. The difference in microstructural origin of fatigue failure between conventionally manufactured and printed metals is reviewed with particular attention to the effects of the trans-scale microstructures on AM fatigue failure mechanisms. Various methods for mitigating the fatigue issue, including pre-process, inter-process, and post-process treatments, are illustrated. Empirical, semi-empirical, and microstructure-sensitive models are presented to predict fatigue strength and lifetime. Summary and outlooks for future development of the fatigue performance of AM materials are provided.

Solute trapping and non-equilibrium microstructure during rapid solidification of additive manufacturing

Solute transport during rapid and repeated thermal cycle in additive manufacturing (AM) leading to non-equilibrium, non-uniform microstructure remains to be studied. Here, a fully-coupled fluid dynamics and microstructure modelling is developed to rationalise the dynamic solute transport process and elemental segregation in AM, and to gain better understanding of non-equilibrium nature of intercellular solute segregation and cellular structures at sub-grain scale during the melting-solidification of the laser powder bed fusion process. It reveals the solute transport induced by melt convection dilutes the partitioned solute at the solidification front and promotes solute trapping, and elucidates the mechanisms of the subsequent microstructural morphology transitions to ultra-fine cells and then to coarse cells. These suggest solute trapping effect could be made used for reducing crack susceptibility by accelerating the solidification process. The rapid solidification characteristics exhibit promising potential of additive manufacturing for hard-to-print superalloys and aid in alloy design for better printability.

Understanding the influence of alloying elements on the print quality of powder bed fusion-based metal additive manufacturing: Ta and Cu addition to Ti alloy

Alloy design coupled with metal additive manufacturing (AM) opens many opportunities for materials innovation. Investigating the effect of printing parameters for alloy design is essential to achieve good part quality. Among different factors, laser absorptivity, heat diffusivity, and in situ intermetallic phase formations are critical. In this study, the first step employed was a reduction in Al and V contents in Ti6Al4V to design Ti3Al2V alloy, and further 10 wt.% tantalum (Ta) and 3 wt.% copper (Cu) were added to Ti3Al2V. A synergistic effect of Ta and Cu addition in Ti3Al2V negated their effect with higher porosities in Ti3Al2V-Ta-Cu. Ti3Al2V-Ta composition was more sensitive to the laser power, whereas Ti3Al2V-Ta-Cu to the overall energy density. Understanding the effect of energy density on these alloys' microstructural evolution and mechanical properties highlights the need for process-property optimization during alloy design using AM.

Benchmarking First-Principles Reaction Equilibrium Composition Prediction

The availability of thermochemical properties allows for the prediction of the equilibrium compositions of chemical reactions. The accurate prediction of these can be crucial for the design of new chemical synthesis routes. However, for new processes, these data are generally not completely available. A solution is the use of thermochemistry calculated from first-principles methods such as Density Functional Theory (DFT). Before this can be used reliably, it needs to be systematically benchmarked. Although various studies have examined the accuracy of DFT from an energetic point of view, few studies have considered its accuracy in predicting the temperature-dependent equilibrium composition. In this work, we collected 117 molecules for which experimental thermochemical data were available. From these, we constructed 2648 reactions. These experimentally constructed reactions were then benchmarked against DFT for 6 exchange-correlation functionals and 3 quality of basis sets. We show that, in reactions that do not show temperature dependence in the equilibrium composition below 1000 K, over 90% are predicted correctly. Temperature-dependent equilibrium compositions typically demonstrate correct qualitative behavior. Lastly, we show that the errors are equally caused by errors in the vibrational spectrum and the DFT electronic ground state energy.