Mechanical properties waammat.com Updated 15 th November 2017 www.cranfield.ac.uk WAAM is a registered trademark of Cranfield University
The deposition strategies Single pass Oscillation Parallel passes 2
Ti64 // Cutting plan for static properties a) Z b) Z Y X X Y 500 locations of coupons deposit 8 22 150 substrate 600 85 3
Ti64 // Static properties Directionality 50 26 Ultimate tensile strength (MPa) 00 950 900 Single Vert. Single Horiz. Par. Vert. Par. Horiz. Oscill. Vert. Oscill. Horiz. Plate Wrought AMS 4928 Horizontal Additive AMS 4999 Vertical Additive AMS 4999 850 750 800 850 900 950 00 4 Elongation (%) 24 22 20 18 16 14 12 8 6 Wrought AMS 4928 Vertical Horizontal Additive AMS 4999 Single Vert. Single Horiz. Par. Vert. Par. Horiz. Oscill. Vert. Oscill. Horiz. Plate 750 800 850 900 950 00
Ti64 // Static properties Average values 60 22 Ultimate tensile strength (MPa) 40 20 00 980 960 940 920 900 880 Single Par. Oscill. Plate Wrought AMS 4928 Additive AMS 4999 860 Cast ASTM F18 750 800 850 900 950 00 5 Elongation (%) 20 18 16 14 12 8 6 Cast ASTM F18 Additive AMS 4999 Wrought AMS 4928 Single Par. Oscill. Plate 750 800 850 900 950 00
Ti64 // Static properties with in-process cold work Directionality 10 26 Ultimate tensile strength (MPa) 50 00 950 900 Unrolled Vert. Unrolled Horiz. 50 kn Vert. 50 kn Horiz. 75 kn Vert. 75 kn Horiz. 75 kn plasma Vert. 75 kn plasma Horiz. Plate Additive AMS 4999 Cast ASTM F18 Wrought AMS 4928 850 750 800 850 900 950 00 50 6 Elongation (%) 24 22 20 18 16 14 12 8 Cast ASTM F18 Additive AMS 4999 Unrolled Vert. Unrolled Horiz. 50 kn Vert. 50 kn Horiz. 75 kn Vert. 75 kn Horiz. 75 kn plasma Vert. 75 kn plasma Horiz. Plate Wrought AMS 4928 6 750 800 850 900 950 00 50
Ti64 // Static properties with in-process cold work Average values 10 22 Ultimate tensile strength (MPa) 50 00 950 900 Cast ASTM F18 Wrought AMS 4928 Additive AMS 4999 850 750 800 850 900 950 00 50 7 Unrolled 50 kn 75 kn 75 kn plasma Plate Elongation (%) 20 18 16 14 12 8 Cast ASTM F18 Additive AMS 4999 Wrought AMS 4928 Unrolled 50 kn 75 kn 75 kn plasma Plate 6 750 800 850 900 950 00 50
Ultimate tensile strength (MPa) Directionality 50 00 950 900 Ti64 // Comparison against other processes Wrought AMS 4928 Horizontal Additive AMS 4999 Norsk Ti from norsktitanium.com; Sciaky from Structure-property correlations for additively manufactured Ti-6Al-4V components produced using directed energy deposition processes, 2016 Proceedings of the 13th World Conference on Titanium Blown-powder from IREPA lasers Laser + Wire from Additive Manufacturing of Ti-6Al-4V: Relationship between Microstructure, Defects and Mechanical Properties, Pia Akerfeldt, PhD Thesis, Lulea Elongation (%) 35 30 25 20 15 Wrought AMS 4928 WAAM Single V. WAAM Single H. WAAM Par. V. WAAM Par. H. WAAM Oscill. V. WAAM Oscill. H. Norsk Ti V. Norsk Ti H. Sciaky V. Sciaky H. Blown powder V. Blown powder H. Laser + wire V. Laser + wire H. Plate Vertical Additive AMS 4999 850 750 800 850 900 950 00 8 Vertical Horizontal Additive AMS 4999 5 750 800 850 900 950 00
Ti64 // Comparison against other processes Average values 60 Norsk Ti from norsktitanium.com; Sciaky from Structure-property correlations for additively manufactured Ti-6Al-4V components produced using directed energy deposition processes, 2016 Proceedings of the 13th World Conference on Titanium Blown-powder from IREPA lasers Laser + Wire from Additive Manufacturing of Ti-6Al-4V: Relationship between Microstructure, Defects and Mechanical Properties, Pia Akerfeldt, PhD Thesis, Lulea 28 Ultimate tensile strength (MPa) 40 20 00 980 960 940 920 900 880 860 Cast ASTM F18 Wrought AMS 4928 Additive AMS 4999 800 850 900 950 00 9 WAAM Single WAAM Par. WAAM Oscill. Norsk Ti Sciaky Blown powder Laser + wire Plate Elongation (%) 26 24 22 20 18 16 14 12 8 6 Cast ASTM F18 Additive AMS 4999 Wrought AMS 4928 WAAM Single WAAM Par. WAAM Oscill. Norsk Ti Sciaky Blown powder Laser + wire Plate 800 850 900 950 00
Ti64 // Fatigue durability High cycle fatigue, Kt = 1 and Kt = 2.3 00 900 R = 0.1, Kt = 1 800 700 Max stress (MPa) 600 500 400 300 200 0 As-dep Vert. As-dep Vert. (run-off) As-dep Horiz. As-dep Horiz. (run-off) Wrought measured by Peters Wrought measured by Peters (trendline) Lamellar by Peters 0 3 4 5 6 7 8 Cycles to failure Property of Airbus
Ti64 // Damage tolerance Fatigue crack growth rate (single bead, without and with cold-work) -5-4 R = 0.1-5 -6 No in-process cold-work da/dn (m/cycle) -7 da/dn (m/cycle) -6-7 In-process cold-worked at 75 kn WAAM: crack across layers WAAM: crack along layers Wrought Ti-6Al-4V (L-T measured) Wrought Ti-6Al-4V (T-L measured) Wrought Ti-6Al-4V (L-T MMPDS) Cast Ti-6Al-4V (MMPDS) -8 0 "K (MPa m 1=2 ) -8-9 WAAM: crack across layers 1 (R = 0.5) WAAM: crack across layers 2 (R = 0.5) WAAM: crack along layers 1 (R = 0.5) WAAM: crack along layers 2 (R = 0.5) Wrought NASA CR2319 (R = 0.5) 0 "K (MPa m 1=2 ) 11
Ti64 // Damage tolerance Fatigue crack growth rate (parallel and oscillated) -4-4 -5 Parallel dep. strategy R = 0.1-5 Oscillation dep. strategy R = 0.1 da/dn (m/cycle) -6-7 No in-process cold-work da/dn (m/cycle) -6-7 No in-process cold-work -8 WAAM: crack across layers Test 1 WAAM: crack across layers Test 2 WAAM: crack along layers Test 1 WAAM: crack along layers Test 2 Wrought Ti-6Al-4V (L-T MMPDS) Cast Ti-6Al-4V (MMPDS) -8 WAAM: crack across layers Test 1 WAAM: crack across layers Test 2 WAAM: crack along layers Test 1 WAAM: crack along layers Test 2 Wrought Ti-6Al-4V (L-T MMPDS) Cast Ti-6Al-4V (MMPDS) -9 0 "K (MPa m 1=2 ) -9 0 "K (MPa m 1=2 ) 12
Ti64 // Damage tolerance Recap FCGR -4-5 All dep. strategies R = 0.1 da/dn (m/cycle) -6-7 No in-process cold-work -8-9 0 "K (MPa m 1=2 ) 13 Single, crack across layers Test 1 Single, crack along layers Test 1 Parallel, crack across layers Test 1 Parallel, crack along layers Test 1 Oscill., crack across layers Test 1 Oscill., crack along layers Test 1 Wrought Ti-6Al-4V (L-T MMPDS) Cast Ti-6Al-4V (MMPDS)
Ti64 // Damage tolerance Fracture toughness 0 90 Across the layers Along the layers 80 K Q or K IC (MPa m 1/2 ) 70 60 50 40 30 20 0 Grade 5 parallel Grade 5 oscillated Grade 23 parallel 14 Wrought Ref: MMPDS thickness > 25 mm plane strain cond. Wrought this research
Ti64 // Properties at the interface Case 1: fully sacrificial Case 2: plate at the bottom Case 3: symmetric structure 15
Ti64 // Crack growth trajectory at the interface WAAM material interface 40 building direction substrate 60 120 3 3 A B C 40 D E 87.5 84 445 AM AM Substrate Crack trajectory maintains almost a straight line Substrate Crack trajectory maintains almost a straight line 16
Ti64 // Crack growth trajectory at the interface WAAM material interface 40 building direction 120 substrate 40 3 3 A B C D E 60 87.5 84 445-5 -5-6 -6 da/dn (m/cycle) -7-8 0 "K (MPa m 1=2 ) Type A Type B Type C Type D Type E Wrought Ti-6Al-4V (L-T) Cast Ti-6Al-4V 17 da/dn (m/cycle) -7 Type A Type B Type C Type D Type E WAAM: crack across layers WAAM: crack along layers -8 0 "K (MPa m 1=2 )
Other titanium alloys (tensile test in progress) Ti-5Al-5Mo-5V-3Cr (5553) à UTS up to 1300 MPa Vickers Hardness Ti 64 Ti 64 high O2 TiB2 coated Ti 5553 Ti 407 Ti64 with 2000ppm O 2 à + 500ppm O 2 = + 70 Mpa Ti64 coated with TiB 2 à grain refinement Timetal 407 à medium strength, high ductility à energy absorption = 1.6 x Ti64 à machinability = 2 x Ti64 352.1 367.3 353.0 416.22 270.09 18
Aluminium 19
Aluminium 2024 All values measured in the horizontal direction 500 13 Ultimate tensile strength (MPa) 450 400 350 300 Unroll. Unroll. T6 15 kn 30 kn 45 kn 45 kn T6 Wrought T6 Elongation (%) 12 11 9 8 Unroll. Unroll. T6 15 kn 30 kn 45 kn 45 kn T6 Wrought T6 250 150 200 250 300 350 400 450 20 7 150 200 250 300 350 400 450
Aluminium 2319 Average values 460 17 Ultimate tensile strength (MPa) 440 420 400 380 360 340 320 300 Unroll. Unroll. T6 15 kn 30 kn 45 kn 45 kn T6 Wrought T6 Elongation (%) 16 15 14 13 12 11 9 Unroll. Unroll. T6 15 kn 30 kn 45 kn 45 kn T6 Wrought T6 280 8 260 120 140 160 180 200 220 240 260 280 300 320 21 7 120 140 160 180 200 220 240 260 280 300 320
Aluminium Safra 66 / ZL205A Thin walls (single beads) Ultimate tensile strength (MPa) 550 500 450 400 350 300 250 Safra 66 Vert. Safra 66 Horiz. Safra 66 Rolled Vert. Safra 66 Rolled Horiz. ZL205A Vert. ZL205A Horiz. ZL205A Rolled Vert. ZL205A Rolled Horiz. ZL205A + T6 Vert. ZL205A + T6 Horiz. ZL205A Rolled + T6 Vert. ZL205A Rolled + T6 Horiz. Desirable Elongation (%) 30 25 20 15 5 Safra 66 Vert. Safra 66 Horiz. Safra 66 Rolled Vert. Safra 66 Rolled Horiz. ZL205A Vert. ZL205A Horiz. ZL205A Rolled Vert. ZL205A Rolled Horiz. ZL205A + T6 Vert. ZL205A + T6 Horiz. ZL205A Rolled + T6 Vert. ZL205A Rolled + T6 Horiz. Desirable 200 0 150 200 250 300 350 400 450 0 0 150 200 250 300 350 400 450 22
Aluminium Safra 66 / ZL205A Thick walls 550 40 Ultimate tensile strength (MPa) 500 450 400 350 300 250 200 Desirable Safra 66 Oscill. Vert. Safra 66 Oscill. Horiz. Safra 66 Parallel Vert. Safra 66 Parallel Horiz. ZL205A Oscill. Vert. ZL205A Oscill. Horiz. ZL205A Oscill. + T4 Vert. ZL205A Oscill. + T4 Horiz. ZL205A Oscill. + T6 Vert. ZL205A Oscill. + T6 Horiz. ZL205A Parallel Vert. ZL205A Parallel Horiz. ZL205A Parallel + T4 Vert. ZL205A Parallel + T4 Horiz. ZL205A Parallel + T6 Vert. ZL205A Parallel + T6 Horiz. 150 50 0 150 200 250 300 350 400 450 Elongation (%) 35 30 25 20 15 5 Desirable Safra 66 Oscill. Vert. Safra 66 Oscill. Horiz. Safra 66 Parallel Vert. Safra 66 Parallel Horiz. ZL205A Oscill. Vert. ZL205A Oscill. Horiz. ZL205A Oscill. + T4 Vert. ZL205A Oscill. + T4 Horiz. ZL205A Oscill. + T6 Vert. ZL205A Oscill. + T6 Horiz. ZL205A Parallel Vert. ZL205A Parallel Horiz. ZL205A Parallel + T4 Vert. ZL205A Parallel + T4 Horiz. ZL205A Parallel + T6 Vert. ZL205A Parallel + T6 Horiz. 0 50 0 150 200 250 300 350 400 450 23
Aluminium 4043 and 5087 Ultimate tensile strength (MPa) Average values 360 340 320 300 280 260 240 220 200 180 4043 5087 5087 + rolling Elongation (%) 22 21.5 21 20.5 20 19.5 4043 5087 5087 + rolling 160 60 80 0 120 140 160 180 200 220 240 24 19 60 80 0 120 140 160 180 200 220 240
Picking the right alloy Ultimate tensile strength (MPa) Average values 600 550 500 450 400 350 300 250 2024 Single 2024 Single T6 2024 15 kn 2024 30 kn 2024 45 kn 2024 45 kn T6 2024 Wrought T6 2319 Single 2319 Single T6 2319 15 kn 2319 30 kn 2319 45 kn 2319 45 kn T6 2319 Wrought T6 5087 Single 5087 Rolled Elongation (%) 22 20 18 16 14 12 8 200 0 150 200 250 300 350 400 450 25 6 0 150 200 250 300 350 400 450
Steels 26
Steels (work in progress) Average values 2000 35 Ultimate tensile strength (MPa) 1500 00 ER70S-6 ER80S-Ni1 ER90S-B3 ER120 Mar. steel 250 Mar. steel 250 HT Mar. steel 350 Mar. steel 350 HT Elongation (%) 30 25 20 15 ER70S-6 ER80S-Ni1 ER90S-B3 ER120 Mar. steel 250 Mar. steel 250 HT Mar. steel 350 Mar. steel 350 HT 500 400 600 800 00 1200 1400 1600 1800 5 400 600 800 00 1200 1400 1600 1800 27
Stainless steels Directionality 10 45 00 17-4 PH Vert. 17-4 PH Horiz. 316L Vert. 316L Horiz. 40 17-4 PH Vert. 17-4 PH Horiz. 316L Vert. 316L Horiz. Ultimate tensile strength (MPa) 900 800 700 Elongation (%) 35 30 25 20 600 15 500 200 300 400 500 600 700 800 900 200 300 400 500 600 700 800 900 28
Inconel 29
Inconel 718 CMT (brushed = mechanical cleaning of surface prior to successive layer) Ultimate tensile strength (MPa) 1500 1400 1300 1200 10 00 900 As-Dep Vert. As-Dep Horiz. As-Dep Vert. (diff. wire) As-Dep Horiz. (diff. wire) As-Dep (brushed) Vert. (diff. wire) As-Dep (brushed) Horiz. (diff. wire) Solutionised Vert. Solutionised Horiz. HT Vert. HT Horiz. CMT AMS 5662 and 5663 Bars, Forgings, & Rings Elongation (%) 50 45 40 35 30 25 20 CMT As-Dep Vert. As-Dep Horiz. As-Dep Vert. (diff. wire) As-Dep Horiz. (diff. wire) As-Dep (brushed) Vert. (diff. wire) As-Dep (brushed) Horiz. (diff. wire) Solutionised Vert. Solutionised Horiz. HT Vert. HT Horiz. 800 15 AMS 5662 and 5663 Bars, Forgings, & Rings 700 300 400 500 600 700 800 900 00 10 1200 300 400 500 600 700 800 900 00 10 1200 30
Inconel 718 Plasma (including cold-work) Ultimate tensile strength (MPa) 1400 1300 1200 10 00 900 800 700 Plasma AMS 5662 and 5663 Bars, Forgings, & Rings As-Dep Vert. As-Dep Horiz. Solutionised Vert. Solutionised Horiz. HT Vert. HT Horiz. Rolled @ 75 kn Vert. Rolled @ 75 kn Horiz. Rolled @ 75 kn + solut. Vert. Rolled @ 75 kn + solut. Horiz. Rolled @ 75 kn + HT Vert. Rolled @ 75 kn + HT Horiz. 600 300 400 500 600 700 800 900 00 10 1200 Elongation (%) 50 45 40 35 30 25 20 15 Plasma As-Dep Vert. As-Dep Horiz. Solutionised Vert. Solutionised Horiz. HT Vert. HT Horiz. Rolled @ 75 kn Vert. Rolled @ 75 kn Horiz. Rolled @ 75 kn + solut. Vert. Rolled @ 75 kn + solut. Horiz. Rolled @ 75 kn + HT Vert. Rolled @ 75 kn + HT Horiz. AMS 5662 and 5663 Bars, Forgings, & Rings 300 400 500 600 700 800 900 00 10 1200 31
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