In-situ hot forging directed energy deposition-arc of CuAl8 alloy

Funding Information: Authors acknowledge the Portuguese Fundação para a Ciência e a Tecnologia ( FCT - MCTES ) for its financial support via the project UID/EMS/00667/2019 (UNIDEMI). VD acknowledges Portuguese Fundação para a Ciência e a Tecnologia ( FCT - MCTES ) for funding the PhD grant SFRH/BD/139454/2018 . TAR acknowledges Portuguese Fundação para a Ciência e a Tecnologia ( FCT - MCTES ) for funding the PhD grant SFRH/BD/144202/2019 . Funding of CENIMAT/i3N by national funds through the Portuguese Fundação para a Ciência e a Tecnologia, I.P., within the scope of Multiannual Financing of R&D Units , reference UIDB/50025/2020–2023 is also acknowledge. This activity has received funding from the European Institute of Innovation and Technology (EIT) Raw Materials through the project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union's Horizon 2020 research and innovation programme. Parts of this research were carried out at PETRA III at DESY, a member of the Helmholtz Association. The research leading to this result has been supported by the project CALIPSOplus under the Grant Agreement 730872 from the EU Framework Programme for Research and Innovation HORIZON 2020 . This project has received funding from the EU-H2020 research and innovation programme under grant agreement No 654360 having benefitted from the access provided by PETRA III at DESY in Hamburg, Germany within the framework of the NFFA-Europe Transnational Access Activity. The authors acknowledge support by OCAS NV and GUARENTEED via Joachim Antonissen. Funding Information: Authors acknowledge the Portuguese Fundação para a Ciência e a Tecnologia (FCT - MCTES) for its financial support via the project UID/EMS/00667/2019 (UNIDEMI). VD acknowledges Portuguese Fundação para a Ciência e a Tecnologia (FCT - MCTES) for funding the PhD grant SFRH/BD/139454/2018. TAR acknowledges Portuguese Fundação para a Ciência e a Tecnologia (FCT - MCTES) for funding the PhD grant SFRH/BD/144202/2019. Funding of CENIMAT/i3N by national funds through the Portuguese Fundação para a Ciência e a Tecnologia, I.P. within the scope of Multiannual Financing of R&D Units, reference UIDB/50025/2020–2023 is also acknowledge. This activity has received funding from the European Institute of Innovation and Technology (EIT) Raw Materials through the project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union's Horizon 2020 research and innovation programme. Parts of this research were carried out at PETRA III at DESY, a member of the Helmholtz Association. The research leading to this result has been supported by the project CALIPSOplus under the Grant Agreement 730872 from the EU Framework Programme for Research and Innovation HORIZON 2020. This project has received funding from the EU-H2020 research and innovation programme under grant agreement No 654360 having benefitted from the access provided by PETRA III at DESY in Hamburg, Germany within the framework of the NFFA-Europe Transnational Access Activity. The authors acknowledge support by OCAS NV and GUARENTEED via Joachim Antonissen. Remark: The supplementary material is temporarily available in the Drive folder here: https://drive.google.com/drive/folders/1SFFlhJlmL5p3IkQis8cB6UVWva3wozGi?usp=sharing. Publisher Copyright: © 2022 Elsevier B.V.CuAl8 alloy finds applications in industrial components, where a good anti-corrosion and anti-wearing properties are required. The alloy has a medium strength and a good toughness with an elongation to fracture at room temperature of about 40%. Additionally, it has a good electrical conductivity, though lower than that of pure Al or pure Cu. Despite these characteristics, additive manufacturing of the CuAl8 alloy was not yet reported. In this work, the direct energy deposition-arc (DED-arc) with and without in-situ hot forging was used to determine the microstructure evolution and mechanical properties. No internal defects were seen on the parts produced. Hot forging combined with DED-arc was seen to reduce and homogenize the grain size, improve mechanical strength and isotropy of mechanical properties. Moreover, the use of this novel DED-arc variant was seen to reduce the magnitude of residual stresses throughout the fabricated part. We highlight that this alloy can be processed by DED-arc, and the hot forging operation concomitant with the material deposition has beneficial effects on the microstructure refinement and homogenization.publishersversionpublishe

microstructure evolution during heat treatments

Funding Information: Authors acknowledge the Portuguese Fundação para a Ciência e a Tecnologia (FCT – MCTES) for its financial support via the project UID/EMS/00667/2019 (UNIDEMI). JPO acknowledges funding by national funds from FCT - Fundação para a Ciência e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020 , UIDP/50025/2020 and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication – i3N. Funding of CENIMAT/i3N by national funds through the FCT-Fundação para a Ciência e a Tecnologia, I.P., within the scope of Multiannual Financing of R&D Units, reference UIDB/50025/2020–2023 is also acknowledge. FWCF acknowledges Fundação para a Ciência e a Tecnologia ( FCT-MCTES ) for funding the Ph.D. Grant 2022.13870. BD. The authors acknowledge DESY (Hamburg, Germany), a member of the Helmholtz Association HGF, for the provision of experimental facilities. Beamtime was allocated for proposal I-20210986 EC. The research leading to this result has been supported by the project CALIPSOplus under the Grant Agreement 730872 from the EU Framework Programme for Research and Innovation HORIZON 2020. This activity has received funding from the European Institute of Innovation and Technology (EIT) Raw Materials through the project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. YZ acknowledges the National Natural Science Foundation of China ( 51601091 ), the Natural Science Foundation of Jiangsu Province ( BK 20160826 ), the Six Talent Peaks Project of Jiangsu Province ( 2017-XCL-051 ), the Fundamental Research Funds for the Central Universities ( 30917011106 ), and Key Research and Development Plan of Jiangsu Province ( BE 2020085 ). Funding Information: Authors acknowledge the Portuguese Fundação para a Ciência e a Tecnologia (FCT – MCTES) for its financial support via the project UID/EMS/00667/2019 (UNIDEMI). JPO acknowledges funding by national funds from FCT - Fundação para a Ciência e a Tecnologia, I.P. in the scope of the projects LA/P/0037/2020, UIDP/50025/2020 and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication – i3N. Funding of CENIMAT/i3N by national funds through the FCT-Fundação para a Ciência e a Tecnologia, I.P. within the scope of Multiannual Financing of R&D Units, reference UIDB/50025/2020–2023 is also acknowledge. FWCF acknowledges Fundação para a Ciência e a Tecnologia (FCT-MCTES) for funding the Ph.D. Grant 2022.13870. BD. The authors acknowledge DESY (Hamburg, Germany), a member of the Helmholtz Association HGF, for the provision of experimental facilities. Beamtime was allocated for proposal I-20210986 EC. The research leading to this result has been supported by the project CALIPSOplus under the Grant Agreement 730872 from the EU Framework Programme for Research and Innovation HORIZON 2020. This activity has received funding from the European Institute of Innovation and Technology (EIT) Raw Materials through the project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. YZ acknowledges the National Natural Science Foundation of China (51601091), the Natural Science Foundation of Jiangsu Province (BK 20160826), the Six Talent Peaks Project of Jiangsu Province (2017-XCL-051), the Fundamental Research Funds for the Central Universities (30917011106), and Key Research and Development Plan of Jiangsu Province (BE 2020085). Publisher Copyright: © 2023 The Author(s)The study reports that the combined use of in situ interlayer hot forging and post-deposition heat treatment (PDHT) could alter the typical coarse and oriented microstructure of the Ni-based superalloy 625 obtained by arc plasma directed energy deposition (DED) to a fine and non-oriented condition. In situ synchrotron X-ray diffraction and electron backscatter diffraction showed that the high-temperature (1100 °C/ 1 h) PDHT induced significant recrystallization, leading to grain refinement and low texture index, while partially dissolving deleterious Laves and δ phases. Low-temperature (980 °C/ 1 h) PDHT had a limited effect on the grain size refinement and induced the formation of secondary phases. It is shown that conventional heat treatments applied to Ni-based superalloy 625 obtained by arc plasma DED are not conducive to optimized microstructure features. In situ hot forging induced enough crystal defects to promote static recrystallization during PDHT. Besides, high-temperature PDHT met the AMS 5662 grain size requirements.publishersversionpublishe

process development and microstructure effects

JPO acknowledges funding by national funds from FCT - Fundação para a Ciência e a Tecnologia, Portugal, I.P. in the scope of the project LA/P/0037/2020. The authors acknowledge DESY (Hamburg, Germany), a member of the Helmholtz Association HGF, for the provision of experimental facilities. Beamtime was allocated for proposal I-20210986 EC. This activity has received funding from the European Institute of Innovation and Technology (EIT) Raw Materials through the project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. YZ acknowledges the National Natural Science Foundation of China (51601091), the Natural Science Foundation of Jiangsu Province (BK 20160826), the Six Talent Peaks Project of Jiangsu Province (2017-XCL-051), the Fundamental Research Funds for the Central Universities (30917011106), and Key Research and Development Plan of Jiangsu Province (BE 2020085). Funding Information: Authors acknowledge the Portuguese Fundação para a Ciência e a Tecnologia (FCT – MCTES) , Portugal, for its financial support via the project UID/EMS/00667/2019 (UNIDEMI). JPO acknowledges funding by national funds from FCT - Fundação para a Ciência e a Tecnologia, Portugal, I.P., in the scope of the projects LA/P/0037/2020 , UIDP/50025/2020 and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication – i3N. FWCF acknowledges Fundação para a Ciência e a Tecnologia ( FCT-MCTES ), Portugal, for funding the Ph.D. Grant 2022.13870. BD . The authors acknowledge DESY (Hamburg, Germany), a member of the Helmholtz Association HGF, for the provision of experimental facilities. Beamtime was allocated for proposal I-20210986 EC. The research leading to this result has been supported by the project CALIPSOplus under the Grant Agreement 730872 from the EU Framework Programme for Research and Innovation HORIZON 2020. This activity has received funding from the European Institute of Innovation and Technology (EIT) Raw Materials through the project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. YZ acknowledges the National Natural Science Foundation of China (51601091), the Natural Science Foundation of Jiangsu Province (BK 20160826), the Six Talent Peaks Project of Jiangsu Province (2017-XCL-051), the Fundamental Research Funds for the Central Universities (30917011106), and Key Research and Development Plan of Jiangsu Province (BE 2020085). Publisher Copyright: © 2023 The AuthorsThe typical as-built coarse and cube-oriented microstructure of Inconel® 625 parts fabricated via arc-based directed energy deposition (DED) induces anisotropic mechanical behavior, reducing the potential applications of arc-based DEDed Inconel® 625 in critical components. In this sense, the present work aimed to reduce the grain size and texture by applying an in situ interlayer hot forging (HF) combined with post-deposition heat treatments (PDHT). The produced samples were characterized through optical microscopy, scanning electron microscopy coupled with electron backscatter diffraction, synchrotron X-ray diffraction, and Vickers microhardness. Also, a dedicated deformation tool was designed and optimized via a finite element method model considering the processing conditions and thermal cycle experienced by the material. It is shown that the in situ interlayer deformation induced a thermo-mechanical-affected zone (dynamic recrystallized + remaining deformation, with a height of ≈ 1.2 mm) at the bead top surface, which resulted in thinner aligned grains and lower texture index in relation to as-built DED counterpart. In addition, the effects of solution (1100 °C/ 1 h) and stabilization (980 °C/ 1 h) PDHTs on the Inconel® 625 HF-DEDed parts were also analyzed, which promoted fine and equiaxed static recrystallized grains without cube orientation, comparable to wrought material. Therefore, the HF-DED process significantly refined the typical coarse and highly oriented microstructure of Ni-based superalloys obtained by arc-based DED.publishersversionpublishe

Prototype of an affordable pressure-controlled emergency mechanical ventilator for COVID-19

We present a viable prototype of a simple mechanical ventilator intended as a last resort to ventilate COVID-19 patients. The prototype implements the pressure-controlled continuous mandatory ventilation mode (PC-CMV) with settable breathing rates, inspiration/expiration time ratios and FiO2 modulation. Although safe, the design aims to minimize the use of technical components and those used are common in industry, so its construction may be possible in times of logistical shortage or disruption or in areas with reduced access to technical materials and at a moderate cost, affordable to lower income countries. Most of the device can be manufactured by modest technical means and construction plans are provided.Comment: This version differs from version 2 in that it includes toxicological and bio-safety tests and updated electronic

In-situ hot forging direct energy deposition-arc of CuAl8 alloy

CuAl8 alloy finds applications in industrial components, where a good anti-corrosion and anti-wearing propertiesare required. The alloy has a medium strength and a good toughness with an elongation to fracture at roomtemperature of about 40%. Additionally, it has a good electrical conductivity, though lower than that of pure Alor pure Cu. Despite these characteristics, additive manufacturing of the CuAl$_8$ alloy was not yet reported. In thiswork, the direct energy deposition-arc (DED-arc) with and without in-situ hot forging was used to determine themicrostructure evolution and mechanical properties. No internal defects were seen on the parts produced. Hotforging combined with DED-arc was seen to reduce and homogenize the grain size, improve mechanical strengthand isotropy of mechanical properties. Moreover, the use of this novel DED-arc variant was seen to reduce themagnitude of residual stresses throughout the fabricated part. We highlight that this alloy can be processed byDED-arc, and the hot forging operation concomitant with the material deposition has beneficial effects on themicrostructure refinement and homogenization

Hot forging wire and arc additive manufacturing (HF-WAAM)

In this study, we propose a new variant of wire and arc additive manufacturing (WAAM) based on hot forging. During WAAM, the material is locally forged immediately after deposition, and in-situ viscoplastic deformation occurs at high temperatures. In the subsequent layer deposition, recrystallization of the previous solidification structure occurs that refines the microstructure. Because of its similarity with hot forging, this variant was named hot forging wire and arc additive manufacturing (HF-WAAM). A customized WAAM torch was developed, manufactured, and tested in the production of samples of AISI316L stainless steel. Forging forces of 17 N and 55 N were applied to plastically deform the material. The results showed that this new variant refines the solidification microstructure and reduce texture effects, as determined via high energy synchrotron X-ray diffraction experiments, without interrupting the additive manufacturing process. Mechanical characterization was performed and improvements on both yield strength and ultimate tensile strength were achieved. Furthermore, it was observed that HF-WAAM significantly affects porosity; pores formed during the process were closed by the hot forging process. Because deformation occurs at high temperatures, the forces involved are small, and the WAAM equipment does not have specific requirements with respect to stiffness, thereby allowing the incorporation of this new variant into conventional moving equipment such as multi-axis robots or 3-axis table used in WAAM

Wire and Arc Additive Manufacturing of High‐Strength Low‐Alloy Steel: Microstructure and Mechanical Properties

Wire and arc additive manufacturing of high-strength low-alloy steel is performed. The microstructures and mechanical properties of the samples are investigated and correlated with the process heat input. Continuous and pulsed wave welding modes are studied and added material efficiencies are determined. The microstructural characterization and microhardness test reveal that the heat input effect is more impactful when parts are produced with pulsed wave mode. Microstrain evolution and phase fraction are evaluated via synchrotron X-ray diffraction. A higher percentage of austenite in the samples built with higher heat input is determined. Uniaxial tensile testing results show that it is possible to improve ductility and mechanical strength by varying the process parameters

Orthogonal cutting of Wire and Arc Additive Manufactured parts

project CARAVELA (POCI-01–0247-FEDER-039796) under the Competitiveness and Internationalization Operational Program, Regional Operational Program for Lisbon FEDER and Portugal 2020. Authors would like to extend their thanks the Portuguese Military Academy Research Center (CINAMIL) for the support provided to high-speed image acquisition. Publisher Copyright: © 2022, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.This work aimed to evaluate whether the established scientific knowledge for machining homogeneous and isotropic materials remains valid for machining additively manufactured parts. The machinability of thin-walled structures produced through two different variants of wire and arc additive manufacturing (WAAM) was studied, namely conventional MIG deposition and the innovative hot forging variant (HF-WAAM). Cutting operations were carried out varying the undeformed chip thickness (UCT) and the cutting speed, using a tool rake angle of 25°. A systematic comparison was made between the existing theoretical principles and the obtained practical results of the orthogonal cutting process, where the relation between the material properties (hardness, grain size, yield strength) and important machining outcomes (cutting forces, specific cutting energy, friction, shear stress, chip formation and surface roughness) is addressed. Additionally, high-speed camera records were used to evaluate the generated shear angle and chip formation process during the experimental tests. The machinability indicators shown that, through the appropriate selection of the cutting parameters, machining forces and energy consumption can be reduced up to 12%, when machining the mechanical improved additive manufactured material. Therefore, it has been confirmed the feasibility of machining such materials following the traditional machining principles, without compromising the surface quality requirements.authorsversioninpres