Piezoelectric-laser ultrasonic inspection and monitoring of thin-walled structure fabricated by directed energy deposition process based on guided waves

Thin-walled metallic structures produced by the Directed Energy Deposition (DED) Additive Manufacturing (AM) process are prone to various fabrication defects, which hinder the wider applications of the technique in practice. In-situ inspection and monitoring methodologies are in high demand for improved quality control of printed parts. This paper presents an ultrasonic guided-wave-based method and a prototype that can potentially be used for in-situ inspection of thin-walled structures produced by DED. Lamb waves are excited by a Lead zirconate titanate (PZT) piezoelectric transducer bonded on the DED substrate remotely from the thin wall. The substrate works as a waveguide to transmit the waves which then propagate along the thin wall. A non-contact laser vibrometer is applied to measure the guide wave signals by scanning the surface of the thin wall. The mechanisms of guided wave generation and propagation along the substrate and printed part are theoretically studied. It allows for choosing proper inspection parameters to enhance the measurement sensitivity of guided waves and help interpret the signals for defect detection. Experiments were conducted with DED-produced stainless steel (316L) thin-walled structure. The new method is demonstrated in one example to detect and localize a small defect caused by inconsistent powder delivery of a fabricated thin wall sample, via analysing the B-scan ultrasonic guided wave signals. The new technique provides strong potential for in-situ online monitoring of the DED process.

Effects of ultrasonic vibration on microstructure and mechanical properties of 1Cr12Ni3MoVN alloy fabricated by directed energy deposition

Due to the rapid melting and solidification during directed energy deposition (DED) process, the defects and columnar crystals are likely to generate in the deposition layers, which reduce the quality and performance of the whole parts. Therefore, in order to improve the microstructure and mechanical properties of 1Cr12Ni3MoVN alloy manufactured by DED method, ultrasonic vibration (UV) has been employed to assist directed energy deposition process in this work. The results indicate that the high-intensity ultrasonic vibration can weaken the epitaxy growth tendency of crystal grains, and significantly improve plasticity while keeping an approximate strength. In addition, a two-dimensional numerical model is established to simulate the effect of ultrasonic vibration in the molten pool. The simulation results show that ultrasonic vibration remarkably improves the flow velocity and pressure in the molten pool, inducing the cavitation effect that breaks dendritic crystal and affects crystal characteristics. Meanwhile, the acoustic streaming effect changes the thermodynamic conditions and promotes high-temperature diffusion, which uniforms temperature distribution and reduces the temperature gradient in the molten pool. Thus the reduced temperature gradient G and raised solidification growth rate R promote the formation of fine equiaxed crystal characteristics after UV treatment. The product G × R increases and the ratio G/R decreases after UV treatment, resulting in the formation of fine equiaxed crystals.

Microstructure enhanced biocompatibility in laser additively manufactured CoCrMo biomedical alloy

The present work investigated biocompatibility of the unique nanostructural surface morphology inherently evolved in laser-based additively manufactured CoCrMo after biocorrosion in simulated body fluid at physiological temperature (37 °C). The extremely rapid thermokinetics intrinsically associated with the laser-based additive manufacturing technique resulted in heterogeneous cellular dendritic solidification morphologies with selective elemental segregation along the cell boundaries within CoCrMo samples. Consequently, a selective and spatially varying electrochemical response resulted in generation of a nanoscale surface morphology (crests and troughs) due to differential localized electrochemical etching. Also, depth of the trough regions was a function of the applied potential difference during potentiodynamic polarization which resulted in samples with varying morphological ratio (depth of trough/width of cell wall). CoCrMo with such nanoscale surface undulations were proposed for enhanced biocompatibility in terms of viability, spreading, and integration of MT3C3 pre-osteoblasts cells elucidated via MTT assay, immunofluorescence, and microscopy techniques. Furthermore, the influence of the morphological ratio, characteristic to the additively deposited CoCrMo after electrochemical etching (biocorrosion) on biocompatibility of MT3C3 pre-osteoblasts cells was qualitatively and quantitatively compared to a mirror-polished flat CoCrMo surface.

Additive manufacturing of Ti-Ni bimetallic structures

Bimetallic structures of nickel (Ni) and commercially pure titanium (CP Ti) were manufactured in three different configurations via directed energy deposition (DED)-based metal additive manufacturing (AM). To understand whether the bulk properties of these three composites are dominated by phase formation at the interface, their directional dependence on mechanical properties was tested. X-ray diffraction (XRD) pattern confirmed the intermetallic NiTi phase formation at the interface. Microstructural gradient observed at the heat-affected zone (HAZ) areas. The longitudinal samples showed about 12% elongation, while the same was 36% for the transverse samples. During compressive deformation, strain hardening from dislocation accumulation was observed in the CP Ti and transverse samples, but longitudinal samples demonstrated failures similar to a brittle fracture at the interface. Transverse samples also showed shear band formation indicative of ductile failures. Our results demonstrate that AM can design innovative bimetallic structures with unique directional mechanical properties.

Designing high-temperature oxidation-resistant titanium matrix composites via directed energy deposition-based additive manufacturing

Composite material development via laser-based additive manufacturing offers many exciting advantages to manufacturers; however, a significant challenge exists in our understanding of process-property relationships for these novel materials. Herein we investigate the effect of input processing parameters towards designing an oxidation-resistant titanium matrix composite. By adjusting the linear input energy density, a composite feedstock of titanium-boron carbide-boron nitride (5 wt% overall reinforcement) resulted in a highly reinforced microstructure composed of borides and carbides and nitrides, with variable properties depending on the overall input energy. Crack-free titanium-matrix composites with hardness as high as 700 ± 17 HV_0.2/15 and 99.1% relative density were achieved, with as high as a 33% decrease in oxidation mass gain in the air relative to commercially pure titanium at 700 °C for 50 h. Single-tracks and bulk samples were fabricated to understand the processing characteristics and in situ reactions during processing. Our results indicate that input processing parameters can play a significant role in the oxidation resistance of titanium matrix composites and can be exploited by manufacturers for improving component performance and high temperature designs.

Hydroxyapatite reinforced Ti6Al4V composites for load-bearing implants

Titanium has been used in various biomedical applications; however, titanium exhibits poor wear resistance, and its bioinert surface slows osseointegration in vivo. In this study, directed energy deposition (DED)-based additive manufacturing (AM) was used to process hydroxyapatite (HA) reinforced Ti6Al4V (Ti64) composites to improve biocompatibility and wear resistance simultaneously. Electron micrographs of the composites revealed dense microstructures where HA was observed at the β-phase grain boundaries. Hardness increased by 57% and 71% for 2 and 3 wt.% HA in Ti64 composites, respectively. XRD analysis revealed no change in the phases with the addition of HA, when compared to the control. Tribological studies displayed an increase in contact resistance (CR) due to an in situ formed HA-based tribofilm, reduction in wear rate when testing in Dulbecco's Modified Eagle Medium (DMEM) with a ZrO₂ counter wear ball, <1% wear ball volume loss, and suppression of cohesive shear failure of the Ti matrix. Histomorphometric analysis from a rat distal femur study revealed an increase in the osteoid surface over the bone surface (OS/BS) for 3 wt.% HA composite over the control Ti64 from 9 ± 1% to 14 ± 1%. Additionally, from push-out testing, the shear modulus was observed to increase from 17 ± 3 MPa for control Ti64 to 32 ± 5 MPa for the 3 wt.% HA composite after 5-weeks in vivo. The present study demonstrates that the addition of HA in Ti64 can simultaneously improve bone tissue-implant response and wear resistance.

Influence of in situ ceramic reinforcement towards tailoring titanium matrix composites using laser-based additive manufacturing

Increasing performance requirements of advanced components demands versatile fabrication techniques to meet application-specific needs. Composite material processing via laser-based additive manufacturing offers high processing-flexibility and limited tooling requirements to meet this need, but limited information exists on the processing-property relationships for these materials as well as how to exploit it for application-specific needs. In this study, Ti/B₄C+BN composites are developed for high-temperature applications by designed-incorporation of ceramic reinforcement (5 wt% total) into commercially-pure titanium to form combined particle and in situ reinforcing phases. We combine both B₄C (limited reactivity with matrix) and BN (high reactivity with matrix) reinforcements to understand the processing characteristics, in situ phase formations, and combinatorial effect of the multiphase microstructures on thermomechanical properties and high-temperature oxidation resistance. Combined reinforcement in this new composite material leads to superior yield strength and wear resistance in comparison to the other compositions and matrix, as well as comparable oxidation characteristics to commercially-developed high temperature titanium alloys, alleviating the need for multiple rare-earth alloying elements that significantly raises costs for manufacturers. Tubular structures are fabricated to demonstrate the ease of site-specific composition and dimensional tolerancing using this method. Our results indicate that tailored ceramic reinforcement in titanium via laser-based AM could lead to significantly enhanced engineering structures, particularly for developing higher temperature titanium-based materials.

Functional Bimetallic Joints of Ti6Al4V to SS410

Bimetallic structures provide a unique solution to achieve site-specific functionalities and enhanced-property capabilities in engineering structures but suffer from bonding compatibility issues. Materials such as titanium alloy (Ti6Al4V) and stainless steel (SS410) have distinct attractive properties but are impossible to reliably weld together using traditional processes. To this end, a laser-based directed energy deposition (DED) system was used to fabricate bimetallic joint of Ti6Al4V and SS410 keeping niobium (Nb) as a diffusion barrier layer. Both shear and compression tests were used to characterize the joint's strength, and compared with the base materials. The bimetallic-joint shear and compressive yield strengths were 419± 3 MPa (~ 114 % of SS410) and 560 ± 4 MPa (~ 169 % of SS410), respectively. The increase in interfacial shear and compressive yield strengths over the base material indicates strong metallurgical bonding between the base materials and the interlayer, Nb. Proof-of-concept part for direct application of the bimetallic joint was demonstrated by welding base metals, end-to-end, to the joint. The interfacial microstructures, elemental diffusion and phases, including failure modes were examined using secondary and backscatter electron imaging, X-ray diffraction (XRD) and energy dispersive spectroscopy (EDS). The bimetallic-joint interfaces were free from brittle intermetallic compounds such as FeTi and Fe₂Ti that are generally responsible for weak bond strength.

Real-time acoustic emission monitoring of powder mass flow rate for directed energy deposition

In order to ensure a reliable and repeatable additive manufacturing process, the material delivery rate in the directed energy deposition (DED) process requires in situ monitoring and control. This paper demonstrates acoustic emission (AE) sensing as a method of monitoring the flow of powder feedstock in a powder fed DED process. With minimal calibration, this signal closely correlates to the actual mass flow rate. This article describes the fabricated mass flow monitoring system, documents various conditions in which the actual flow rate deviates from its set value, and details situations that highlight the system's utility. While AE mass flow monitoring is not free of concerns, its features make it an attractive measurement technique in the powder-fed DED process. The work presented here highlights the results obtained and illustrates that accurate monitoring of powder flow in real-time regardless of environmental conditions within the build chamber is possible.

Data indicating temperature response of Ti-6Al-4V thin-walled structure during its additive manufacture via Laser Engineered Net Shaping

An OPTOMEC Laser Engineered Net Shaping (LENS(™)) 750 system was retrofitted with a melt pool pyrometer and in-chamber infrared (IR) camera for nondestructive thermal inspection of the blown-powder, direct laser deposition (DLD) process. Data indicative of temperature and heat transfer within the melt pool and heat affected zone atop a thin-walled structure of Ti-6Al-4V during its additive manufacture are provided. Melt pool temperature data were collected via the dual-wavelength pyrometer while the dynamic, bulk part temperature distribution was collected using the IR camera. Such data are provided in Comma Separated Values (CSV) file format, containing a 752×480 matrix and a 320×240 matrix of temperatures corresponding to individual pixels of the pyrometer and IR camera, respectively. The IR camera and pyrometer temperature data are provided in blackbody-calibrated, raw forms. Provided thermal data can aid in generating and refining process-property-performance relationships between laser manufacturing and its fabricated materials.