Grain boundary network evolution in electron-beam powder bed fusion nickel-based superalloy Inconel 738

Additive manufacturing (AM) of alloys has attracted much attention in recent years for making geometrically complex engineering parts owing to its unique benefits, such as high flexibility and low waste. The in-service performance of AM parts is dependent on the microstructures and grain boundary networks formed during AM, which are often significantly different from their wrought counterparts. Characteristics such as grain size and morphology, texture, and the detailed grain boundary network are known to control various mechanical and corrosion properties. Advanced understanding on how AM parameters affect the formation of these microstructural characteristics is hence critical for optimising processing parameters to unlock superior properties. In this study, the difficult-to-weld nickel-based superalloy Inconel 738 was fabricated via electron-beam powder bed fusion (EPBF) following linear and random scanning strategies. Random scanning resulted in finer, less elongated, and crystallographically more random grains compared to the linear strategy. However, both scanning strategies achieve unique high grain structure stability up to 1250 ℃ due to the presence of carbides pinning the grain boundaries. Despite significant difference in texture and morphology, majority of grains terminated on {100} habit planes in both linear and random built samples. The results show potential for controlling grain boundary networks during EPBF by tuning scan strategies

Nano-twining and deformation-induced martensitic transformation in a duplex stainless steel 2205 fabricated by laser powder bed fusion

Duplex stainless steels (DSSs) possess desirable combinations of mechanical properties and excellent corrosion resistance due to their composition and equilibrium microstructure of roughly equivalent fractions of ferrite and austenite. They are used in harsh environments such as marine infrastructures, oil & gas, and paper & pulp industries. Components with complex geometries are often required for these applications. Additive manufacturing (AM) techniques such as laser powder bed fusion (LPBF) can be harnessed to fabricate components with greatest complexity. However, AM fabrication is well-known to promote non-equilibrium microstructures with high dislocation densities and Cr2N precipitates, resulting in inferior ductility. This is generally regarded as a challenge, however, short heat treatments of such as-built microstructures have been shown to attain refined duplex equilibrium microstructures. Recently, annealed LPBF DSS 2205 has been reported to possess strength higher than wrought counterparts and ductility properties better than the as-built state. However, the microstructural phenomena and deformation mechanisms behind these attractive properties remain poorly understood. Through multi-scale microstructural characterization, we show that the improved strength results not only from the hard ferrite phase, but also fine austenite grain size and nanoscale oxide dispersion strengthening. The enhanced ductility may be attributed to a combination of deformation mechanisms including dislocation slip, stacking fault formation, deformation twinning, and a deformation-induced martensitic transformation. We discuss how the level of microstructural complexity and solid-state phase transformations during LPBF and annealing can unlock multiple strengthening mechanisms during tensile deformation. Such fundamental understanding is crucial for designing AM parts with reproducible and optimised mechanical properties

Effect of compositional variations on the heat treatment response in 17-4 PH stainless steel fabricated by laser powder bed fusion

17–4 precipitate hardening (PH) stainless steel is used in various applications including in the aerospace, marine, and chemical industries, largely due to its unique combination of corrosion resistance and high strength, which is achieved by the formation of nanoscale Cu-rich precipitates during aging. 17–4 PH has been widely researched for its applicability for laser powder bed fusion (LPBF). However, there are discrepancies in the literature on its heat treatment response, which seem to be linked to compositional variations. Systematic studies of the interplay between these variations and nanoscale precipitation are currently missing. Using atom probe tomography, we present a systematic study of the heat treatment responses of two variants of LPBF 17–4 PH builds fabricated from different powder feedstocks, with significant differences in N contents (High vs Low N 17–4). Both variants formed predominantly δ-ferritic as-built microstructures. The as-built High N 17–4 variant showed a higher volume fraction of austenite which further increased upon solution annealing and quenching. The consequence was no appreciable hardening effect due to the absence of Cu precipitation in either austenite or martensite after aging, degrading the alloy's desirable property profile. Conversely, Low N 17–4 showed no austenite in the as-built condition and a fully martensitic matrix after solution annealing. This variant had the desired aging response; a ∼ 140 HV 5 increase in hardness due to nanoscale Cu precipitation. Our findings describe the deleterious effects of compositional variations incurred during the LPBF process flow and how they can be overcome in 17–4 PH and similar steels

Microstructure, texture and tensile properties of ultrafine/nano grained magnesium alloy processed by accumulative back extrusion

An AZ31 wrought magnesium alloy was processed by employing multipass accumulative back extrusion process. The obtained microstructure, texture and room temperature tensile properties were characterized and discussed. Ultrafine grained microstructure including nano grains were developed, where the obtained mean grain size was decreased from 8 to 0.5 µm by applying consecutive passes. The frequency of both low angle and high angle boundaries increased after processing. Strength of the experimental alloy was decreased after processing, which was attributed to the obtained texture involving the major component lying inclined to the deformation axis. Both the uniform and post uniform elongations of the processed materials were increased after processing, where a total elongation of 68 pct was obtained after six-pass deformation. The contribution of different twinning and slip mechanism was described by calculating corresponding Schmid factors. The operation of prismatic slip was considered as the major deformation contributor. The significant increase in post uniform deformation of the processed material was discussed relying on the occurrence of grain boundary sliding associated with the operation of prismatic slip.Postprint (author's final draft

Evolution of microstructure and crystallographic texture during dissimilar friction stir welding of duplex stainless steel to low carbon-manganese structural steel

Electron backscattered diffraction (EBSD) was used to analyze the evolution of microstructure and crystallographic texture during friction stir welding of dissimilar type 2205 duplex stainless steel (DSS) to type S275 low carbon-manganese structural steel. The results of microstructural analyses show that the temperature in the center of stirred zone reached temperatures between Ac 1 and Ac 3 during welding, resulting in a minor ferrite-to-austenite phase transformation in the S275 steel, and no changes in the fractions of ferrite and austenite in the DSS. Temperatures in the thermomechanically affected and shoulder-affected zones of both materials, in particular toward the root of the weld, did not exceed the Ac 1 of S275 steel. The shear generated by the friction between the material and the rotating probe occurred in austenitic/ferritic phase field of the S275 and DSS. In the former, the transformed austenite regions of the microstructure were transformed to acicular ferrite, on cooling, while the dual-phase austenitic/ferritic structure of the latter was retained. Studying the development of crystallographic textures with regard to shear flow lines generated by the probe tool showed the dominance of simple shear components across the whole weld in both materials. The ferrite texture in S275 steel was dominated by D 1, D 2, E, E¯ , and F, where the fraction of acicular ferrite formed on cooling showed a negligible deviation from the texture for the ideal shear texture components of bcc metals. The ferrite texture in DSS was dominated by D 1, D 2, I, I¯ , and F, and that of austenite was dominated by the A, A¯ , B, and B¯ of the ideal shear texture components for bcc and fcc metals, respectively. While D 1, D 2, and F components of the ideal shear texture are common between the ferrite in S275 steel and that of dual-phase DSS, the preferential partitioning of strain into the ferrite phase of DSS led to the development of I and I¯ components in DSS, as opposed to E and E¯ in the S275 steel. The formations of fine and ultrafine equiaxed grains were observed in different regions of both materials that are believed to be due to strain-induced continuous dynamic recrystallization (CDRX) in ferrite of both DSS and S275 steel, and discontinuous dynamic recrystallization (DDRX) in austenite phase of DSS

Power and Energy Engineering Conference (APPEEC), 2015 IEEE PES Asia-Pacific

The incorporation of distributed PV generation data into power system planning and operation is becoming increasingly important as penetrations of PV systems on Australian distribution networks continue to grow. However, the availability of such data is currently very limited. The APVI Live PV Map (Live Map) provides near real-time distributed PV generation estimates in 57 different regions across Australia based on some 6000 PV systems reporting their generation online. This data has a wide range of potential applications including, for example, network planning or PV performance assessment. In this paper we investigate the characteristics of the PV systems contributing to the Live Map database, in order to assess its accuracy and suitability for providing total distributed PV generation estimates for power system planning and operational purposes. The study compares the sample of PV systems contributing data to the Live Map database with the total set of PV systems in Australia, according to the Clean Energy Regulator's (CER's) database. Representativeness is assessed in terms of PV system location, size, age, and inverter manufacturer. The accuracy of the APVI Live Map PV generation estimates for individual regions is assessed by comparison with a separate database of historical interval metered household PV generation from the Ausgrid network. Finally, an example of the application of distributed PV data to electricity network planning is provided to highlight the potential value of these PV generation estimates