In situ interlayer hot forging arc-based directed energy deposition of Inconel® 625: process development and microstructure effects

Farias, Francisco Werley Cipriano; Duarte, Valdemar R.; Felice, Igor Oliveira; Filho, João da Cruz Payão; Schell, Norbert; Maawad, Emad; Ávila, Julián A.; Li, J.Y.; Zhang, Y.; Santos, Telmo G.; Oliveira, J.P.

doi:10.1016/j.addma.2023.103476

Cited by 11 publications

(8 citation statements)

References 78 publications

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“…In addition, Duarte et al [20] observed the increase in the cooling rate due to the higher bead width after the hot deformation, which promoted a finer primary microstructure (e.g., cellular and dendritic). Farias et al [111,112] clarified the grain refinement mechanisms of the DEDed-arc + interlayer hot forging (Fig. 13).…”

Section: Non-transformable Solid-state Alloysmentioning

confidence: 96%

“…The hammer path planning followed the torch, and the hammer size, and distance from the welding pool control the forging temperature. Duarte et al [20] and Farias et al [111,112] showcased that hot forging could reduce pore size, alter its morphology, and improve the mechanical properties of 316L stainless steel and Inconel 625 DEDed-arc. In addition, Gao et al [113] customized a machine that combined DED-arc and single-point incremental hot forming, which operated at a maximum load of 1.5 kN, refined the microstructure, and improved the mechanical properties of 316L stainless steel DEDed-arc.…”

Section: Hammering Peening and Forgingmentioning

confidence: 99%

“…The authors [111,112], using in situ electron X-ray diffraction, reported that interlayer hot forging could generate enough crystal defects to induce static recrystallization during subsequent thermal cycles and post-deposition heat DEDed-laser, reported that the interlayer hot ultrasonic micro-forging did not alter the typical columnar and oriented grains, which is mainly controlled by heat transfer aspects during part building. Additionally, Li et al [109] highlighted that the CET depth, which is related to dynamic recrystallization, increased from 440 to 840 µm, which indicates that the interlayer hot ultrasonic micro-forging recrystallized the CET grains (Fig.…”

Section: Non-transformable Solid-state Alloysmentioning

confidence: 99%

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Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Farias,

dos Santos,

Oliveira

2024

Int J Adv Manuf Technol

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Directed energy deposition (DED) additive manufacturing systems have been developed and optimized for typical engineering materials and operational requirements. However, parts fabricated via DED often demonstrate a diminished material response, encompassing inferior mechanical properties and heat treatment outcomes compared to traditionally manufactured components (e.g., wrought and cast materials). As a result, parts produced by DED fail to meet stringent specifications and industry requirements, such as those in the nuclear, oil and gas, and aeronautics sectors, potentially limiting the industrial scalability of DED processes. To address these challenges, systems integrating DED with interlayer (cold or hot) mechanical deformation (e.g., rolling and hammering/peening, forging) have been developed. These systems refine the microstructure, mitigate the typical crystallographic texture through static and/or dynamic recrystallization, and enhance mechanical properties and heat treatment responses without altering material specifications. In this regard, the present state-of-the-art review reports the DED + interlayer mechanical deformation systems and their variants, and their potential and limitations, providing a critical analysis to support the development and adaptation of this technology to overcome the process and material limitations that currently prevent the large-scale industrial adoption of DED processes. Furthermore, a detailed description of the grain size refinement mechanisms induced by interlayer mechanical deformation and their respective effects on the mechanical properties of commonly used 3D-printed engineering alloys (e.g., Ti-6Al-4V, Inconel 718, various low-alloy steels, AISI 316L stainless steel, and Al-based series 2xxx) is comprehensively analyzed.

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Section: Non-transformable Solid-state Alloysmentioning

confidence: 96%

Section: Hammering Peening and Forgingmentioning

confidence: 99%

Section: Non-transformable Solid-state Alloysmentioning

confidence: 99%

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Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Farias,

dos Santos,

Oliveira

2024

Int J Adv Manuf Technol

Self Cite

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“…Cooper et al [80] used SDM and CNC milling to form multi-material polymer-ceramic parts. More recently, Farias et al [81,82] utilized an arc-based DED process integrated with in situ interlayer hot forging and post-deposition heat treatments to significantly refine the typical coarse and highly oriented microstructure of Ni-based superalloy 625. It was observed that the in situ hot forging induced abundant crystal defects that led to the promotion of static recrystallization during post-deposition heat treatments.…”

Section: Hybrid Additive Manufacturing (Ham) Processesmentioning

confidence: 99%

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

et al. 2023

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Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM’s capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.

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“…As a subset of metal additive manufacturing, Directed Energy Deposition-Arc (DED-Arc) utilizes electric arcs to melt and spray material onto the workpiece surface, layer by layer, to build up components [6,7]. The process improves working efficiency [8].…”

Section: Introductionmentioning

confidence: 99%

Forming Control via Interval Width in Directed Energy Deposition-Arc Process

Wang,

Xie

et al. 2024

Metals

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A novel controller, employing a variable-structure single-neuron adaptive PSD (proportional integral derivative) approach, was proposed for regulating the deposition width variation in the Directed Energy Deposition-Arc (DED-Arc) layer. During experimental trials, the deposition speed was chosen as the manipulated variable, while the width of the deposition layer served as the measured parameter. To facilitate controller design, a vision sensor was custom-designed to accurately detect the width of the deposition layer. The captured image of the deposition layer’s dimensions enabled the precise determination of the deposited thickness, forming the basis for subsequent controller development. In performance assessments, deliberate interference was intentionally introduced into the deposition current, deposition layer height, and the targeted deposition layer width. The assessment involved the controlled deposition of ten-layer components, focusing on width regulation for each deposition layer. The results demonstrate that the proposed controller significantly enhances the deposition process stability, particularly within a range of desired deposition widths from 7.5 mm to 8.3 mm.

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In situ interlayer hot forging arc-based directed energy deposition of Inconel® 625: process development and microstructure effects

Cited by 11 publications

References 78 publications

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

Directed energy deposition + mechanical interlayer deformation additive manufacturing: a state-of-the-art literature review

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

Forming Control via Interval Width in Directed Energy Deposition-Arc Process

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