Evaluation of Microstructure, Residual Stress, and Mechanical Properties in Different Planes of Wire + Arc Additive Manufactured Nickel-Based Superalloy

Kumar, Mithilesh; Manoharan, Manikandan

doi:10.1007/s12540-022-01185-w

Cited by 26 publications

(4 citation statements)

References 75 publications

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“…400 MPa of the tensile residual stresses in the corner areas was exhibited that could be traced back to a higher design-related shrinkage restraint corresponding to commonly known models. These results were qualitatively comparable with other studies; e.g., on WAAM of IN718 [8,20]. However, the ratio of yield strength to residual stress was lower here.…”

Section: Cooling Time During Additive Manufacturingsupporting

confidence: 93%

“…Other authors investigated these local effects due to high temperature gradients, and found significant influences on the local stress distributions and magnitudes [21], as well as complex interactions with superimposing global welding stresses due to high shrinkage restraints [7]. In comparison to other studies with materials that did not undergo a solidphase transformation during cooling, which influenced the residual stresses; e.g., [8,20], there was an overall change in the stress equilibrium up to an overall reduction in the residual stresses, which can be specifically utilized, or is already systematically exploited by special material developments [22]. It is therefore important to clarify which of these effects dominates and contributes significantly to the local residual stress formation.…”

Section: Residual Stress Analysismentioning

confidence: 99%

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Influence of Heat Control on Properties and Residual Stresses of Additive-Welded High-Strength Steel Components

Scharf-Wildenhain

André

Hensel

et al. 2022

Metals

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Advanced high-performance filler metals for wire arc additive manufacturing (WAAM) exist on the market already. Nevertheless, these high-strength steels are not yet widely used in industrial applications due to limited knowledge of cold-cracking susceptibility, welding residual stresses, and therefore sufficient safety in terms of manufacturing and operation. High residual stresses promote cold-cracking risk, especially in the welding of high-strength steels, as the result of a complex interaction between the applied material, process conditions, and component design. The focus of the present investigation was the determination of the influence of the process parameters on the ∆t8/5 cooling time, mechanical properties, and residual stresses to correlate, for the first time, heat control, cooling conditions, and residual stress for WAAM of high-strength filler materials. This contributed to the knowledge regarding the safe avoidance of cold cracking. In addition to a thermophysical simulation using a dilatometer of different high-strength steels with subsequent tensile testing, reference WAAM specimens (open hollow cuboids) were welded while utilizing a high-strength filler metal (ultimate tensile strength >790 MPa). The heat control was varied by means of the heat input and interlayer temperature such that the ∆t8/5 cooling times corresponded to the recommended processing range (approx. 5 s to 20 s). For the heat input, significant effects were exhibited, in particular on the local residual stresses in the component. Welding with an excessive heat input or deposition rate may lead to low cooling rates, and hence to unfavorable microstructure and component properties, but at the same time, is intended to result in lower tensile residual stress levels. Such complex interactions must ultimately be clarified to provide users with easily applicable processing recommendations and standard specifications for an economical WAAM of high-strength steels. These investigations demonstrated a major influence of the heat input on both the cooling conditions and the residual stresses of components manufactured with WAAM using high-strength filler materials. A higher heat input led to longer cooling times (∆t8/5) and approx. 200 MPa lower residual stresses in the surface of the top layer.

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Section: Cooling Time During Additive Manufacturingsupporting

confidence: 93%

Section: Residual Stress Analysismentioning

confidence: 99%

Influence of Heat Control on Properties and Residual Stresses of Additive-Welded High-Strength Steel Components

Scharf-Wildenhain

André

Hensel

et al. 2022

Metals

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“…A narrower and average bead and the ideal penetration depth improve welding multiple passes. 13 The reduced width-to-height proportions and depth of weld passes may be attributed to incomplete melting and insufficient heat accumulation. However, a distorted bead structure can develop during multi-pass welding.…”

Section: Experimental Studymentioning

confidence: 99%

Arc-welded armour steel: A tailored and comparative study of its microstructure and mechanical properties

Sathish Kumar,

Arivazhagan

2024

Proceedings of the Institution of Mechanical Engineers, Part L:

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The present research aims to investigate and analyse the metallurgical features, including macrostructure, microstructure, scanning electron microscopy with energy-dispersive X-ray spectroscopy, and electron backscatter diffraction. In addition, the mechanical properties of the arc welding specimens, encompassing hardness, tensile properties, and impact toughness at room temperature, were determined. The specimens were joined utilising various welding techniques, including gas tungsten arc welding, gas metal arc welding, shielded metal arc welding, and flux-cored arc welding. According to macrography, the weldments have no porosity, inclusions, or penetration. This confirms the optimal weldment fabrication process parameters. An optical microstructure analysis was conducted on various zones of the weldments. The weld fusion zone's microstructure reveals delta (δ) ferrite within the austenite matrix. A two-phase microstructure of bainite and untempered martensite is observed in the heat-affected zone. Scanning electron microscopy images at higher magnification reveal austenite and partially δ-ferrite phases. Energy-dispersive X-ray spectroscopy analysis showed higher chromium, nickel, manganese, silicon, and molybdenum concentrations on the grain boundary than in the matrix. According to electron backscatter diffraction, the average weld zone grain sizes for gas tungsten arc welding, gas metal arc welding, shielded metal arc welding, and flux-cored arc welding are 21.4, 35.8, 25.8, and 34.3 µm, respectively. In the heat-affected zone, the grain size decreased significantly. The welding region has lower mechanical properties than the heat-affected zone. All specimens produced using different welding processes had no cracking in the weld metal, including the fusion zone and border.

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“…As one of the most popular metal additive manufacturing techniques, selective laser melting (SLM) technology uses a focused laser to selectively melt powder along the certain route and quickly bond it to form a part layer by layer [8]. Compared with other metal additive manufacturing technologies, SLM has the advantages of high forming accuracy and good surface finish [9,10].…”

Section: Introductionmentioning

confidence: 99%

Influence of scanning speed on microstructures and mechanical properties of SLM produced Hastelloy X: as-built and solution-treated

Li,

Zhang,

Wang

et al. 2024

Mater. Res. Express

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Hastelloy X (HX) alloys with ideal strength and ductility match can be obtained by selective laser melting (SLM) and a proper follow-up heat treatment. This work studies the influence of scanning speed on grain size, grain boundary distribution, recrystallization and mechanical properties of as-built HX. These influences are reevaluated after a solution treatment at 1175 °C for 4h. The results reveal that the average grain size decreases, while the aspect ratio, texture intensity and the proportion of high-angle grain boundaries (HAGBs) increases with the increase of scanning speed. A small amount of recrystallization has occurred in the as-built alloys due to the cyclic thermal effect of SLM scanning. The finer grains and larger aspect ratio imply the higher energy storage during SLM, which will increase the recrystallizing nucleation rate. Solution treatment eliminates the fiber texture of 〈100〉//BD, significantly increases the HAGBs fraction and recrystallization fraction, reduces the grain aspect ratio, and coarsens the grains. With the increase of scanning speed, the strength of the Hastelloy X increases and the elongation decreases. The decrease of grain size is the main reason for the increase of yield strength.

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Evaluation of Microstructure, Residual Stress, and Mechanical Properties in Different Planes of Wire + Arc Additive Manufactured Nickel-Based Superalloy

Cited by 26 publications

References 75 publications

Influence of Heat Control on Properties and Residual Stresses of Additive-Welded High-Strength Steel Components

Influence of Heat Control on Properties and Residual Stresses of Additive-Welded High-Strength Steel Components

Arc-welded armour steel: A tailored and comparative study of its microstructure and mechanical properties

Influence of scanning speed on microstructures and mechanical properties of SLM produced Hastelloy X: as-built and solution-treated

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