Effect of post processing on the creep performance of laser powder bed fused Inconel 718

In this study, the creep performance of laser powder bed fusion manufactured Inconel 718 specimens is studied in detail and compared with conventional hot-rolled specimens alongside as-built then heat-treated and as-built then hot-isostatic pressed specimens. Hot-rolled specimens showed the best creep resistance, while the hot-isostatic pressed specimens yielded the worst performance, inferior to the as-built condition. Creep testing of all samples showed increased secondary creep rate was consistently correlated with a reduced life. Fractography revealed intergranular fracture was the primary failure mode for all as-built samples. Preferential intergranular precipitation in the case of the hot-isostatic pressed specimens during hot-isostatic pressing extensive intergranular cracking as the primary failure mechanism. Heat-treated specimens possessed only sparse intergranular precipitates, thereby explaining an improved creep lifetime. The hot-rolled specimens, having smallest grain size, showed the least extensive cracking, particularly in locations of finest grains, explaining avoidance of intergranular fracture as a key creep mechanism, thereby explaining the ductile creep fracture surfaces in the case of the hot-rolled samples

Electrolyte jet machining for surface texturing of Inconel 718

Electrolyte jet machining is an emerging non-conventional machining process which is capable of selectively applying multi-scale surface textures. Surfaces processed in this way do not suffer from thermal damage and hence this technique is highly suited to finishing procedures in high value manufacturing across the aerospace and biomedical sectors. Furthermore, input variables can be modified dynamically to create functional graduation across component surfaces. In this study, the development and design of a custom-built EJM system is described, and the capability of the EJM platform to machine and create surface textures in Inconel 718, a widely used nickel based super alloy, is investigated. Through control of machine path programming and parameter variation, multi-scale surface textures are created which have the potential to enhance bonding with subsequent coating layers and also provide fluid dynamic advantage

Spheroidisation of metal powder by pulsed electron beam irradiation

A new powder spheroidisation process has been demonstrated using a large-area, pulsed electron beam technique. This was used to dramatically improve the surface morphology of Stellite 6 metal powder. Powder surface asperities up to 20 μm size can be eliminated by melting and incorporation into the near-surface of the particle. Surface finish is significantly improved. Agitation and rotation of particles due to a beam-induced stress wave enables the irradiation of multiples sides of particles, resulting in uniformly smoothed particles after sufficient pulses. Elemental analysis revealed no measurable contamination as a result of the process. Transmission electron microscopy showed a dense layer is produced within a zone up to 3 μm beneath the surface, with a substantially reduced grain size from ca. 2 μm diameter in the bulk to ca. 40 nm. Elemental homogenisation also was accompanied by grain refinement. The irradiated Stellite 6 showed a reduced basic flowability energy (583 mJ compared to 627 mJ for the untreated), explained by reduced particle-particle cohesion and interlocking, and an increased conditioned bulk density of 4.57 g/ml compared to 4.33 g/ml due to satellite/asperity reduction

Erosion resistance of laser clad Ti-6Al-4V/WC composite for waterjet tooling

AbstractIn waterjet operations, milled surfaces are left with some undesirable dimensional artefacts, thus the use of abrasion resistant mask has been proposed to improve the surface quality of machined components. In this study, the erosion performance of laser clad Ti-6Al-4V/WC composite coating subjected to plain water jet (PWJ) and abrasive water jet (AWJ) impacts to evaluate its potentials for use as waterjet impact resistant mask material and coating on components was investigated. Results showed that composite with 76wt.% WC composition subjected to PWJ and AWJ impacts offered resistance to erosion up to 13 and 8 times that of wrought Ti-6Al-4V respectively. Scanning electron microscopy (SEM) examination of the eroded composite surfaces showed that the erosion mechanism under PWJ impacts is based on the formation of erosion pits, tunnels and deep cavities especially in the interface between the WC particles and the composite matrix owing to lateral outflow jetting and hydraulic penetration. Composite suffered ploughing of the composite matrix, lateral cracking and chipping of embedded WC particles and WC pull-out under AWJ impacts. The composite performance is attributed to the embedded WC particles and the uniformly distributed nano-sized reaction products (TiC and W) reinforcing the ductile β-Ti composite matrix, with its mean hardness enhanced to 6.1GPa. The capability of the Ti-6Al-4V/WC composite coating was demonstrated by effective replication of a pattern on a composite mask to an aluminium plate subjected to selective milling by PWJ with an overall depth of 344μm. Thus, composite cladding for tooling purpose would make it possible to enhance the lifetime of jigs and fixtures and promote rapid machining using the water jet technique

Functionally graded Ni-Ti microstructures synthesised in process by direct laser metal deposition

The fabrication of biomedical devices using Ni-Ti compositions is limited to conventional techniques and the use of near equiatomic pre-alloyed Ni and Ti powders. In this study, functionally graded walls and cylinder built by concurrent feeding of Ni powder and commercially pure (CP) Ti wire using direct laser metal deposition technique are presented. The built structures consist of CP Ti wire-deposited layers and Ni-Ti layers of varying Ni composition. The microstructures of the built Ni-Ti structures including phase identification, phase compositions and area fractions of the phases present at various processing parameters were determined using a combination of scanning electron microscopy/ energy dispersive X-ray spectroscopy, X-ray diffractometry and image processing software. Vickers microhardness test was conducted on the deposited structures. It was found that the Ni-Ti layers comprise of NiTi and NiTi2 phases. The area fraction of the NiTi phase increases, whereas NiTi2 decreases with increasing the Ni powder feed rate. Ni-Ti layers with higher area fractions of NiTi2 phase are found to be harder with a maximum of 513 HV0.3 found in this study. The micro-hardness of Ni-Ti layers is, by at least a factor of 1.5, higher than the CP Ti wire laser-deposited layers

Soluble abrasives for waterjet machining

© 2014 Taylor & Francis Group, LLC. The addition of hard abrasives to the jet in waterjet machining can improve machining rate, however, embedding of particles in machined surfaces is a limitation, which results in reduced fatigue life, and limits the application of well adhered subsequent coatings to the surface. In this study, softer soluble abrasives were investigated as a potential solution. Soluble abrasives yielded a higher material removal rate compared to plain waterjet, although were not as effective as traditional hard abrasives. Soluble abrasives reduced grit embedment on all four workpiece materials. A post-machining surface cleaning operation demonstrated that any remaining soluble abrasive could be removed

Development of metal matrix composites by direct energy deposition of ‘satellited’ powders

Limited research has been undertaken investigating the material design freedoms that are granted through the use of additive manufacturing methods, especially in the development of materials specifically formulated for additive processes. In this study, a new material combination was evaluated for use with directed energy deposition methods of additive manufacturing. Here, a Ti-6Al-4 V powder is processed in combination with a much finer titanium diboride powder following a satelliting procedure. The resulting combination consists of large Ti-6Al-4 V particles encased in finer titanium diboride. Deposited composites presented exhibit TiB needles associated with increased hardness. Processing conditions were detailed which permit the deposition of the prepared feedstock onto Ti-6Al-4 V substrates. Microstructural characterisation revealed that the composite was made up of eutectic TiB precipitates dispersed in α-β Ti matrix with few partially melted Ti-6Al-4 V and TiB2 particles. Satelliting TiB2 powder onto Ti-6Al-4 V particle surfaces has significantly improved the homogeneity of composite which is characterised with randomly oriented and uniform distribution of TiB needles in the microstructure. Hardness of composites ranged between 440–480 HV. Hence, the feedstock preparation method proposed has been found to be effective and can be adapted for low cost and rapid formulation of a host of materials for processing by additive manufacture

Driving next generation manufacturing through advanced metals characterisation capability

Understanding the effects of manufacturing methods upon materials has driven constant innovation for over 300 years. While our ability to fabricate metallurgical wonders extends into the annals of history our ability to understand the scientific principles where process meets material has been pivotal to improving our capabilities. In this letter we briefly consider this history, comment upon the current state-of-the-art and, most importantly, propose new technologies for future industrial application which have been devised and exploited by the authors. It is hoped that this letter will allow other researchers to engage in this topic and facilitate the emergence of new processcompatible technologies which do not require destructive evaluation. This is particularly timely given the ability to manipulate microstructures with increasing dexterity. This is perhaps best illustrated in additive manufacturing [1] but is also a key consideration when process planning for machining [2], grinding [3] and forming [4]

Salt-metal feedstocks for the creation of stochastic cellular structures with controlled relative density by powder bed fabrication

A novel type of metallic feedstock material for powder-bed additive manufacturing (AM) processes is proposed that enables the manufacture of cellular structures without the time consuming and computationally intensive step of digitally representing the internal geometry of a part. The feedstock is a blend of metal and salt particles and, following Selective Laser Melting (SLM) processing, the salt is dissolved to leave a metallic, cellular structure. The conditions for successfully processing the feedstock are first demonstrated, followed by an investigation into how the feedstock composition can be used to control the relative density of the cellular material. Mechanical testing reveals that the strength and stiffness of the cellular structures can be tuned through control of feedstock composition, and hence, relative density. This presents a significant enhancement to the state-of-the-art for materials preparation for AM since, for the first time, cellular structures can be created with specific properties without explicitly defining or analysing the unit cell geometry

Physical and electrical characteristics of EDM debris

AbstractIn EDM, debris plays a key role in the electrical conditions of the discharge gap prior to each spark. Despite this, analysis of debris at all length-scales has not yet been performed, and therefore the nature of debris produced by electrical discharge processes is not fully understood. In this study debris created by the machining of two electrode materials set as negative polarity, silicon and titanium carbide, was centrifuged and imaged using SEM and TEM. From this analysis it was shown that electrode debris is 1nm or lower and up to 10μm in size. Population analysis of the particle size distribution was used to inform an electric field model based on a lattice Boltzmann method framework, simulating the effect of the presence of such debris on the electric field strength. This method is shown to be able to capture the local variation of the electric field and predict qualitatively the correct trend of the electric field strength increasing against the debris concentration. Such data is important for prediction and control of discharge gap size, as well as understanding the impact of a build-up of debris on uncontrolled sparking