Interface strength and mechanical properties of Inconel 718 processed sequentially by casting, milling, and direct metal deposition

Soffel, Fabian; Eisenbarth, Daniel; Hosseini, E.; Wegener, Konrad

doi:10.1016/j.jmatprotec.2020.117021

Cited by 31 publications

(20 citation statements)

References 16 publications

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“…For the qualification of AM processes, it is essential to analyze the mechanical properties of the deposited material. A previous study of the authors [ 26 ] investigated the microstructural evolution and tensile properties of Inconel 718 deposited by DMD without laser remelting on cast IN718 substrates. Here, tensile testing of the interface specimens showed that the interface is not the critical zone under tensile load, as the fracture location was within the cast section, where the material has a lower yield strength due to its larger grains.…”

Section: Resultsmentioning

confidence: 99%

Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys

et al. 2021

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Nickel-based super alloys are popular for applications in the energy and aerospace industries due to their excellent corrosion and high-temperature resistance. Direct metal deposition (DMD) of nickel alloys has reached technology readiness for several applications, especially for the repair of turbomachinery components. However, issues related to part quality and defect formation during the DMD process still persist. Laser remelting can effectively prevent and repair defects during metal additive manufacturing (AM); however, very few studies have focused on numerical modeling and experimental process parameter optimization in this context. Therefore, the aim of this study is to investigate the effect of determining the remelting process parameters via numerical simulation and experimental analyses in order to optimize an industrial process chain for part repair by DMD. A heat conduction model analyzed 360 different process conditions, and the predicted melt geometry was compared with observations from a fluid flow model and experimental single tracks for selected reference conditions. Subsequently, the remelting process was applied to a demonstrator repair case. The results show that the models can well predict the melt pool shape and that the optimized remelting process increases the bonding quality between base and DMD materials. Therefore, DMD part fabrication and repair processes can benefit from the remelting step developed here.

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Section: Resultsmentioning

confidence: 99%

Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys

et al. 2021

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“…Therefore, Inconel 718, a Ni-Cr-Fe austenite (γ) superalloy [ 1 , 2 , 5 ] has been mostly employed in turbojet engines in the form of major parts of turbines wheel, discs and blades. It is also used in rocket engines, combustion chambers and nuclear reactors as it offers robustness and prevents the occurrence of brittle transformation in the components at high temperatures [ 1 , 2 , 3 , 4 , 5 , 6 , 7 ].…”

Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

“…This equipment is composed of a lifting platform (1), an electromagnetic field inducer ( 5) and an induction coil (8). In this figure, the position of the ceramic shell (2), pouring cup (3), ceramic crucible (4), ceramic filter ( 6), nickel penny (7) and the Inconel ingot ( 9), inside the chamber when the lifting platform is raised and the door closed, is visible. During the process, after the raise of the lifting platform and subsequently close of the chamber door, vacuum was applied in the casting chamber before the Inconel ingot melting (vacuum melting start value: 0.1 mbar), aiming to avoid the occurrence of oxidation reactions.…”

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confidence: 99%

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Grain Refinement of Inconel 718 Superalloy—The Effect of Rotating Magnetic Field

et al. 2022

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The effect of the application of a rotating magnetic field on the average grain size of IN718 castings was experimentally studied. For the purpose, four parts were produced by investment casting and characterized. The first casting was produced without application of RMF for comparison. The remaining ones were submitted to different RMF frequencies for 15 min and subsequently to the pouring of the nickel-based superalloy. In these three castings, the RMF frequencies applied were, respectively, 15 Hz, 75 Hz and 150 Hz. All the other process parameters were kept constant during the execution of the experimental procedure. The average grain size of the samples was determined according to the ASTM E112-13 standard, using intercept methods. Macro hardness measurements, tensile testing and SEM-EDS analysis were conducted in order to evaluate the casting’s mechanical properties and microstructures. The results demonstrate a noticeable grain size reduction in the samples submitted to rotating magnetic field. An average grain area reduction, greater than 96%, was achieved in the castings where RMF frequencies of 75 Hz and 150 Hz were applied. The application of RMF also caused a morphological change in the casting’s dendrites from cellular to almost equiaxed. Additionally, it originated the decrease of the size and amount of needle-like δ phase. Regarding mechanical properties of the cast parts, no major differences were verified.

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“…To increase the built rate, surface quality, and shape accuracy of parts manufactured by DMD, the process can be combined with conventional manufacturing techniques. Soffel et al [9] showed that casting, milling, and DMD can be combined to fabricate parts efficiently and with mechanical properties exceeding conventional manufacturing methods. As highlighted by Eisenbarth et al [10], the process sequence for the combination of additive and subtractive manufacturing is of high importance for the dimensional accuracy of the final part.…”

Section: Introductionmentioning

confidence: 99%

Effect of clad height, substrate thickness and scanning pattern on cantilever distortion in direct metal deposition

Soffel

Eisenbarth

Wegener

2021

Int J Adv Manuf Technol

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In metal additive manufacturing, moving heat sources cause spatial and time-dependent variations of temperature and strain that can lead to part distortions. Distortion prediction and optimized deposition parameters can increase the dimensional accuracy of the generated components. In this study, an analytical approach for modeling the effect of clad height and substrate thickness is experimentally validated. Additionally, the influence of the scanning pattern as a function of clad height and substrate thickness is determined experimentally. The analytical model is based on the cool-down phase mechanism and assumes the formation of constant thermal shrinking forces for each deposited layer. The model accurately predicts longitudinal cantilever distortion after experimental calibration when compared with similar experimental conditions. For multi-layer deposition, the scanning pattern has the largest influence on distortion for thin-walled substrates. An optimized deposition strategy with longitudinal scanning vectors leads to a distortion reduction of up to 86%. The results highlight the potential of mechanical modeling and scanning strategy optimizations to increase the shape accuracy for industrial applications in the field of additive manufacturing.

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Interface strength and mechanical properties of Inconel 718 processed sequentially by casting, milling, and direct metal deposition

Cited by 31 publications

References 16 publications

Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys

Laser Remelting Process Simulation and Optimization for Additive Manufacturing of Nickel-Based Super Alloys

Grain Refinement of Inconel 718 Superalloy—The Effect of Rotating Magnetic Field

Effect of clad height, substrate thickness and scanning pattern on cantilever distortion in direct metal deposition

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