Additive manufacturing of oxide-dispersion strengthened alloys: Materials, synthesis and manufacturing

Wilms, Markus Benjamin; Rittinghaus, Silja‐Katharina; Goßling, Mareen; Gökce, Bilal

doi:10.1016/j.pmatsci.2022.101049

Cited by 57 publications

(9 citation statements)

References 480 publications

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“…The results of the SLS method include a variety of defects, such as size faults, layer delamination, porosity, and subpar material qualities [ 2 ]. These defects could be visible in the finished products.…”

Section: Introductionmentioning

confidence: 99%

Thermal Modeling of Polyamide 12 Powder in the Selective Laser Sintering Process Using the Discrete Element Method

et al. 2023

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Selective laser sintering (SLS) is one of the key additive manufacturing technologies that can build any complex three-dimensional structure without the use of any special tools. Thermal modeling of this process is required to anticipate the quality of the manufactured parts by assessing the microstructure, residual stresses, and structural deformations of the finished product. This paper proposes a framework for the thermal simulation of the SLS process based on the discrete element method (DEM) and numerically generated in Python. This framework simulates a polyamide 12 (PA12) particle domain to describe the temperature evolution in this domain using simple interaction laws between the DEM particles and considering the exchange of these particles with the boundary planes. The results obtained and the comparison with the literature show that the DEM frame accurately captures the temperature distribution in the domain scanned by the laser. The effect of laser power and projection time on the temperature of PA12 particles is investigated and validated with experimental settings to show the reliability of DEM in simulating powder-based additive manufacturing processes.

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Section: Introductionmentioning

confidence: 99%

Thermal Modeling of Polyamide 12 Powder in the Selective Laser Sintering Process Using the Discrete Element Method

et al. 2023

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“…Oxide dispersion strengthened (ODS) nickel (Ni)-based superalloys, represented by MA754 and MA6000 (tradename of Inco Alloys International), are a class of advanced materials comprising a Ni-based matrix that is reinforced with finely dispersed nano-scale oxide particles, such as Y 2 O 3 , YAlO 3 and Y 2 Ti 2 O 7 . [1][2][3][4][5] Unlike the 𝛾′/𝛾′′ strengthening precipitates formed in many Ni superalloys such as Inconel 625, Inconel 718 (IN718) and Inconel 738, which tend to dissolve as they approach their solvus temperatures, these oxide particles have a markedly higher melting point than the matrix in which they are embedded. This unique feature enables them to effectively impede dislocation glide even at temperatures close to the melting point of Ni-based superalloys, particularly when they are homogeneously distributed in the consolidated products with a diameter smaller than 50 nm (or more precisely with an interparticle spacing less than 500 nm).…”

Section: Introductionmentioning

confidence: 99%

“…This unique feature enables them to effectively impede dislocation glide even at temperatures close to the melting point of Ni-based superalloys, particularly when they are homogeneously distributed in the consolidated products with a diameter smaller than 50 nm (or more precisely with an interparticle spacing less than 500 nm). [5][6][7] As a result, ODS Ni-based superalloys can achieve remarkable performance in terms of tensile and creep (rupture) strength in hightemperature environments, even beyond 1000 °C. These outstanding characteristics make them highly suitable for demanding applications in aerospace, power generation, and nuclear industries, such as turbine blades, combustion chambers, and nuclear reactor components.…”

Section: Introductionmentioning

confidence: 99%

Unique Yttria Nanoparticle Strengthening in an Inconel 718 Superalloy Fabricated by Additive Manufacturing

Dai,

Zhu,

Yan

et al. 2023

Adv Materials Technologies

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Oxide dispersion strengthened (ODS) nickel (Ni)‐based superalloys are advanced materials known for their outstanding tensile and creep performance at temperatures exceeding 1000 °C. Nevertheless, their conventional synthesis presents a longstanding challenge in cost‐effectively producing intricate components for critical applications. In this work, electrostatic self‐assembly (ESA) of powders with the laser powder bed fusion (LPBF) process have been successfully combined to produce yttria ODS Inconel 718 (IN718) alloy for the first time. The approach has demonstrated a significant contribution of yttria to the strength of IN718 after the solid solution heat treatment, as evidenced by ≈50% improvement in room temperature yield strength with a 0.5 wt.% yttria addition. The addition of yttria by this process leads to a heterogeneous microstructure. This heterogeneous microstructure comprises two distinct grain areas with varying amounts of yttria nanoparticles and dislocation storage. It has been shown that the yield strength increase can be predicted by the combination of both Y2O3 dispersion strengthening and dislocation strengthening mechanisms. These findings offer an effective approach to tailor heterogeneous microstructures, unlocking new opportunities for cost‐effectively producing high‐performance ODS Ni‐based superalloy products with excellent mechanical properties.

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“…This will undoubtedly bring huge challenges to machining and forming, as traditional forming processes, such as casting, forging, injection molding, have difficulties in preparing complex internal structural components. Additive manufacturing is based on the principle of layer-by-layer stacking to form components, providing a high degree of freedom in material design and manufacturing, and can prepare components of nearly any complex shape [ 4 , 5 , 6 ]. Therefore, in recent years, additive manufacturing has received increasing attention and research in the preparation of complex metal components.…”

Section: Introductionmentioning

confidence: 99%

“…At present, the representative powder-bed-based additive manufacturing methods entering the field of metal manufacturing include laser powder bed fusion (LPBF) [ 6 , 7 , 8 , 9 ] and binder jet printing (BJP) [ 10 , 11 ]. And laser powder bed melting (LPBF) can also be further categorized into two techniques: selective laser melting (SLM) [ 7 , 12 , 13 ], which mainly uses a fiber laser or YAG laser, and selective laser sintering (SLS), which mainly uses a CO 2 laser [ 14 , 15 , 16 ].…”

Section: Introductionmentioning

confidence: 99%

Investigation on the Attainment of High-Density 316L Stainless Steel with Selective Laser Sintering

Zhu,

He,

Guan

et al. 2023

Materials

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Due to the low density of the green part produced by selective laser sintering (SLS), previous reports mainly improve the sample’s density through the infiltration of low-melting metals or using isostatic pressing technology. In this study, the feasibility of preparing high-density 316L stainless steel using 316L and epoxy resin E-12 as raw materials for SLS combined with debinding and sintering was investigated. The results indicated that in an argon atmosphere, high carbon and oxygen contents, along with the uneven distribution of oxygen, led to the formation of impurity phases such as metal oxides, including Cr2O3 and FeO, preventing the effective densification of the sintered samples. Hydrogen-sintered samples can achieve a high relative density exceeding 98% without losing their original design shape. This can be attributed to hydrogen’s strong reducibility (effectively reducing the carbon and oxygen contents in the samples, improving their distribution uniformity, and eliminating impurity phases) and hydrogen’s higher thermal conductivity (about 10 times that of argon, reducing temperature gradients in the sintered samples and promoting better sintering). The microstructure of the hydrogen-sintered samples consisted of equiaxed austenite and ferrite phases. The samples exhibited the highest values of tensile strength, yield strength, and elongation at 1440 °C, reaching 513.5 MPa, 187.4 MPa, and 76.1%, respectively.

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Additive manufacturing of oxide-dispersion strengthened alloys: Materials, synthesis and manufacturing

Cited by 57 publications

References 480 publications

Thermal Modeling of Polyamide 12 Powder in the Selective Laser Sintering Process Using the Discrete Element Method

Thermal Modeling of Polyamide 12 Powder in the Selective Laser Sintering Process Using the Discrete Element Method

Unique Yttria Nanoparticle Strengthening in an Inconel 718 Superalloy Fabricated by Additive Manufacturing

Investigation on the Attainment of High-Density 316L Stainless Steel with Selective Laser Sintering

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