Laser melting functionally graded composition of Waspaloy® and Zirconia powders

Abstract

An approach for fabricating functionally graded specimens of supernickel alloy and ceramic compositions via Selective Laser Melting (SLM) is presented. The focus aimed at using the Functionally Graded Material (FGM) concept to gradually grade powdered compositions of Zirconia within a base material of Waspaloy ® . A high power Nd:YAG laser was used to process the material compositions to a high density with gradual but discrete changes between layered compositions. The graded specimens initially consisted of 100% Waspaloy ® with subsequent layers containing increased volume compositions of Zirconia (0-10%).Specimens were examined for porosity and microstructure. It was found that specimens contained an average porosity of 0.34% with a gradual change between layers without any major interface defects.

Chemical analysis, structure and mechanical properties of discrete and compositionally graded SS316–IN625 dual materials

“…Liu et al [8] reported that they could fabricate crack free Ti-TiC FGMs by varying 0 to 95 vol% TiC using LENS™. Mumtaz and Hopkinson [9] reported that local heat transfer conditions affect porosity within the YSZ-Waspalloy FGM made by Selected Laser Melting technique. Unocic et al [10] studied the effect of LENS process parameters on dilution and hence compositional variation in FGMs.…”

A brief review of functionally graded materials

“…There are various types of SFF innovations, even so, the laser based forms are mostly utilized in creating functional graded material [6]. Laser based SFF process for FGM [7] include: (i) laser cladding based strategy [8,9], and (ii) Selective Laser Sintering (SLS) [10,11]. SFF includes five essential steps [12].…”

Selective Laser Sintering/Melting

“…Some researchers have tried to make FGM with present systems (116)(117)(118). Beal et al tried to make a tool by changing the proportion of materials (copper and tool steel), which is the most used material in tooling.…”