Suorakerrostuksen materiaalit, ominaisuudet ja sovellukset

Transcription

1 Suorakerrostuksen materiaalit, ominaisuudet ja sovellukset J. Tuominen, TkT Tampereen teknillinen yliopisto Materiaaliopin laboratorio Laser Application Laboratory

2 Outline Directed energy deposition (DED) (definition) DED methods Feedstock types: o Powder o Wire o Strip Type of metal alloys: o Properties o Applications Summary 2

3 Directed energy deposition (DED) ISO/ASTM 52900:2016 Additive manufacturing General principles Terminology o DED is AM process in which focused thermal energy (laser, EB, plasma-arc) is used to fuse materials by melting as they are being deposited o The build surface can be an existing part onto which material is added (repairing) 3

4 DED methods Others: Additive friction stir welding Strip cladding (SAW, ESW, laser) Cold spraying Laser: coax-powder Laser: coax-wire (cold, hot), off-axis wire (cold, hot) EB: coax-wire (xbeam) EB: off-axis wire (Sciaky) MIG/MAG, MIG/MAG pulsed, CMT TIG cold-, hot-wire Plasma-arc (powder, wire) 4

5 Powders Produced by atomization: o Gases (Ar, He, N 2 ) (spherical shape) o Plasma (spherical, smooth, high purity, for reactive metals) o Water (irregular) o Centrifugal (spherical, smooth, for reactive metals) Production methods affect: o Shape (flowability, absorption) o Surface texture (moisture?) o Porosity (mechanical properties) o satellites (flowability) o Size (resolution, surface finish, flowability, efficiency) 1. Melting 2. Atomization 3. Solidification o Purity (S, P, O) (defects, inclusions, mechanical properties) Gas atomized PTA grade typically used (50-150µm) 5

6 Wires Solid wires (soft & ductile by drawing) (Ø mm) Low alloy grades often Cu coated Tubular wires (Ø 1.2mm) Metal sheath: Lubricant coated (graphite, MoS 2 ) Internal powders: Alloying elements (metals, carbides etc.) Arc stabilizers Fluxing agents Slag formers Shielding gas producers 1. Strip 2. U-forming rolls 3. Flux/powder 4. Closing Seamless by electrical resistance welding Abutting Lapped Single or Multi-folded Guest 2014, Canada 6

7 Strips Strips for SAW & ESW (w= mm, t=0.5mm) o Solid (rolling) o Sintered (from powders, Stellites for instance) o Flux-cored (thick) Strip-wires (w= mm, t= mm) o Produced by rolling round wires or cutting from wider bands o To increase deposition rates, better surface quality o Less penetration o G3Si1, AlMg4.5Mn, AlSi5 Fronius International GmbH 7

8 Materials Low alloy steels (G3Si1,4130, 4140, 300M) Tool steels (P20, M4, H13, CPM 10V, X42Cr13) Hadfield-steels (12-19%Mn, %C, 0-2.5%Cr) Maraging steels (low C ultra high strength) Invar steels (low CTE: 2.5 x 10-6, FeNi36) Stainless steels (316L, 254SMO, 2205, 431, 17-4 PH, S53) Hardfacing alloys (Stellites, Norem, Nanosteel, Self-fluxing alloys) Superalloys (Inconel, Hastelloy, Monel, CMSX-4, René, high-cr NiCr) Titanium alloys (Ti-6Al-4V, Ti6242, Ti grade 2) Aluminium alloys (2000-, 4000, 5000-series) Magnesium alloys Copper alloys (CuAl, NiAl bronze, CuSn, CuSi 3, CuNi) Refractory metals (W, Mo, Ta) MMCs (WC/W 2 C-NiBSi, VC-tool steel, SiC-Al, synthetic diamonds) Special embeddings: solid lubricants (MoS 2, WS 2, CaF 2, graphite), optical fiber Intermetallics (Cr 13 Ni 5 Si 2, MoSi 2, FeAl,, TiAl, NiTi) Gradient layers (FGM) (metal matrix composites, monolithes) Development of new alloys (high entropy alloys, glassy metals) 8

9 Low alloy steels 11mm 11mm Arc-DED wire: Cantilever beam, (Cranfield University, UK), topology optimized, 7m, 1500kg 300M as-weld: R m ~1500MPa E ~200GPa H HV Arc-DED wire: Excavator boom, carbon steel (Oak Ridge National Laboratory, 2017, USA) Hybrid manufactured (additive + subtractive) mild steel 70S-6 (Song et al. 2005, South Korea) Arc-DED wire: 300M UHSS (Skiba et al. 2010) S355: R m MPa 9

10 Tool steels Laser-DED powder: Conformal cooling channels in cooling fan mold of H13 (InssTek, South Korea) (B. Dutta, POM, 2012, USA) Laser-DED powder: Graded build-up of laser clad gear teeth, hot-work tool steel (Laser Cladding Venture, NV, Belgium) Arc-DED wire: Austenitic martensitic VC tool steel (~850HV 1 ), crack-free (Tuominen 2016) (Griffith et al., 2000, USA) EB-DED wire: Build-up and repair of tooling & stamping dies (Sciaky Inc., USA) 10

11 Maraging, Invar steels 1100 MPa Laser-DED wire: Maraging 250 steel test block on H13 for die casting tool applications M. Kottman, M.Sc. Thesis, 2015 Kottman et al. JOM 67(3) 2015 Arc-DED wire: Invar steel (Yan 2013, Cranfield University) 11

12 Stainless steels Lying Standing Arc-DED wire: Blade with CMT, duplex SS 2209 (Posch, Fronius Int. GmbH) FN Laser-DED powder: Corrosion resistant UHSS Ferrium S53 landing gear (TWI, UK) Laser-DED powder: (Rombouts et al. 2012, Belgium) 12

13 Hardfacing alloys Laser-DED powder: Stellite 21 (Freisse et al., 2015, Germany) Laser-DED powder: In-situ repair of turbine blades with Stellite 6 (TWI Ltd, UK) Laser-DED powder: Colmonoy-6 sleeve (Paul 2006) Arc-DED wire: Fe-based, 42 HRC (TUT 2017) 13

14 Superalloys Inconel 625 wrought: UTS 855 MPa Yield 490 MPa Laser-DED powder: IN-718 impeller (Xue et al., 2011, Canada) Laser-DED powder: Inconel 625 (Rombouts et al. 2012) Laser-DED powder: IN738 (Chen & Xue, 2010, Canada) Laser-DED powder: Single crystal & directionally solidified alloys (Krause 2001) 14

15 Superalloys True Stress Samples E (MPa) Rp 0,2 (MPa) Rm (MPa) Ru (MPa) A% W W W Av P P P Av Characterization of CMT clad Alloy 718 deposit Internship trainee Anthony Camacho (Tuominen 2017) 15

16 Ti alloys A large 3D printed titanium part for J-20 or J-31 stealth fighter (China) UTS Yield Ti-6Al-4V as built (Dutta 2017) Different AM techniques generate different solidification and cooling rates: -> various crystal structures and phases Laser-DED powder:ti-6al-4v (TWI, UK) 16

17 Ti alloys x-direction y-direction z-direction Suorakerrostettu Ti-6Al-4V (laserjauhe) as-built (Dutta 2017) 17

18 Al alloys Arc-DED wire: Stiffened Al panels (Cranfield University, UK) Arc-DED wire: Wing rib (Cranfield University, UK) R a 3.0µm Hypoeutectic AlSi5 (4043) by robot-guided CMT process, 50 HV 0.05 (Tuominen et al., 2014) 150 layers 40 mm 3 /s Arc-DED wire: Tensile performances of Al alloys (Martina 2015, Cranfield University, UK) 18

19 Mg alloys Laser-DED powder: Elektron MAP 43 Mg (T. Palmer, PennState, USA) 19

20 Cu alloys Arc-DED wire: Brass (Posch, Fronius Int. GmbH, Austria) Laser-DED powder: Drawing die with cooling channels, CuAl10Fe1 (aluminium bronze) (Freisse et al., 2015, Germany) Arc-DED wire: Brass sculpture (MX3D, Netherlands) Arc-DED wire: NiAl bronze (Ding et al., 2016, Australia) 20

21 Refractory metals Arc-DED wire: (Williams 2016, Cranfield Unversity, UK) 21

22 Intermetallics Laser-DED powder: TiAl (Fraunhofer ILT, Germany) Arc-DED wire: TiAl (Ma et al., 2015, Australia) Laser-DED powder: TiAl (Fraunhofer IWS, Germany) Arc-DED wire: FeAl (Shen et al., 2015, Australia) 22

23 Multi-material Laser-DED powder: Nickel/Copper, hybrid (additive + subtractive) (Kerschbaumer et al., 2004) Laser-DED powder: SS/NiCr/Ti6Al4V (Sahasrabudhe et al., 2015, USA) Arc-DED wire: Steel/Bronze (CuSi3) (Cranfield University, UK) 23

24 FGM Laser-DED powder: In690/TiC FGM (Wilson et al., 2012) Laser-DED powder: NiBSi/WC, NiBSi/CrC FGM, cutting-edge of circular knife (Theiler et al., BIAS Bremen) Laser-DED powder: Graded stainless steel 316L / Stellite 6 (Smurov 2007) Arc-DED wire: Fe-FeAl FGM (Shen et al., 2015) 24

25 Special embeddings Arc-DED wire: Single mode optical fiber in metal (Martina 2015, Cranfield University, UK) Laser-DED powder: Inconel Cr 3 C 2 + WS 2 (PennState, USA) 25

26 Summary Feedstock materials in powder, wire and strip forms Several material options: steels, Ni-based superalloys, aluminium, titanium, Cu-based alloys etc. Multi-materials, FGMs, MMCs, intermetallics Hard and brittle metals & alloys the most challenging Directionally solidified structures -> anisotropic mechanical properties Mechanical properties decrease if structural defects caused by process parameters or inadequate quality of feedstock material (post-treatment helps in some cases) THANK YOU! 26