Oxidation induced mechanisms during directed energy deposition additive manufactured titanium alloy builds

Iantaffi, Caterina; Leung, Chu Lun Alex; Chen, Yunhui; Guan, Shaoliang; Atwood, Robert C.; Lertthanasarn, Jedsada; Pham, Minh‐Son; Meisnar, Martina; Rohr, Thomas; Lee, Peter

doi:10.1016/j.addlet.2021.100022

Cited by 13 publications

(8 citation statements)

References 57 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…It is well known [1] that the convective flow of liquid metal is mainly driven by the spatial gradient of surface tension (Marangoni effect) and buoyancy. High-speed imaging has shown that the Marangoni effect on the gas bubble dynamics is important only near the pool surface [77]. However, a gas bubble often nucleates near the bottom surface, where buoyancy may play a more crucial role [78].…”

Section: Escape Velocity Of Gas Bubblesmentioning

confidence: 99%

Mitigation of Gas Porosity in Additive Manufacturing Using Experimental Data Analysis and Mechanistic Modeling

Sinha,

Mukherjee

2024

Materials

View full text Add to dashboard Cite

Shielding gas, metal vapors, and gases trapped inside powders during atomization can result in gas porosity, which is known to degrade the fatigue strength and tensile properties of components made by laser powder bed fusion additive manufacturing. Post-processing and trial-and-error adjustment of processing conditions to reduce porosity are time-consuming and expensive. Here, we combined mechanistic modeling and experimental data analysis and proposed an easy-to-use, verifiable, dimensionless gas porosity index to mitigate pore formation. The results from the mechanistic model were rigorously tested against independent experimental data. It was found that the index can accurately predict the occurrence of porosity for commonly used alloys, including stainless steel 316, Ti-6Al-4V, Inconel 718, and AlSi10Mg, with an accuracy of 92%. In addition, experimental data showed that the amount of pores increased at a higher value of the index. Among the four alloys, AlSi10Mg was found to be the most susceptible to gas porosity, for which the value of the gas porosity index can be 5 to 10 times higher than those for the other alloys. Based on the results, a gas porosity map was constructed that can be used in practice for selecting appropriate sets of process variables to mitigate gas porosity without the need for empirical testing.

show abstract

Section: Escape Velocity Of Gas Bubblesmentioning

confidence: 99%

Mitigation of Gas Porosity in Additive Manufacturing Using Experimental Data Analysis and Mechanistic Modeling

Sinha,

Mukherjee

2024

Materials

View full text Add to dashboard Cite

show abstract

“…There are also other research works [127][128][129] on the L-PBF of Ti-6242, detailing which are beyond the capacity of the current text. Lantaffi et al [130] evaluated the build environment effects on the microstructural features of Ti-6242 alloy produced via DED. The amount of oxygen absorbed from the atmosphere during localized shielding gas processing inverted the Marangoni flow, altering the molten pool geometry and significantly impacting defect formation.…”

Section: L-pbfmentioning

confidence: 99%

Additive Manufacturing of Titanium Alloys: Processability, Properties, and Applications

Mosallanejad,

Abdi,

Karpasand

et al. 2023

Adv Eng Mater

View full text Add to dashboard Cite

The restricted number of materials available for additive manufacturing (AM) technologies is a determining impediment to AM growing into sectors and providing supply chain relief. AM, in particular, is regarded as a trustworthy manufacturing technology to replace the traditional ones for Ti alloy components. Furthermore, the AM processability of Ti alloys and their features, such as microstructure, texture, and mechanical properties, is strongly dependent on the chemical composition of the processed alloy. It is essential to consider the ultimate applications as well. β Ti alloys are gaining popularity in the biomedical industry, while α + β Ti alloys are increasingly utilized for producing components in the automotive and aerospace sectors. Consequently, the topic has garnered considerable interest, and the current text reviews the advances during the last 10 years in this area to facilitate the pathway from the demanded Ti alloy to the best‐fit AM procedure. While systematically reviewing the works published in the literature, the current text attempts to establish a link between the production method, feedstock type, chemical composition, and the ultimate application. This review also features practical applications of Ti components produced by metal AM methods and offers prospective possibilities and industrial applications.

show abstract

“…At low oxygen concentrations, oxygen atoms enter into the octahedral interstitial sites of the α-phase, improving the properties of the solid solution. On the contrary, at high oxygen levels, embrittlement occurs, which reduces the tensile strength, ductility, and fracture toughness of Ti alloys [131]. One method for preventing air contamination is to process the material in an inert gas chamber, under vacuum, or with a localized inert gas shield.…”

Section: Additive Manufacturing Of Titanium and Its Alloysmentioning

confidence: 99%

Sustainable Recovery of Titanium Alloy: From Waste to Feedstock for Additive Manufacturing

Tebaldo,

Gautier di Confiengo,

Duraccio

et al. 2023

Sustainability

View full text Add to dashboard Cite

Titanium and its alloys are widely employed in the aerospace industry, and their use will increase in the future. At present, titanium is mainly produced by the Kroll method, but this is expensive and energy-intensive. Therefore, the research of efficient and sustainable methods for its production has become relevant. The present review provides a description of the titanium recycling methods used to produce mostly aeronautical components by additive manufacturing, offering an overview of the actual state of the art in the field. More specifically, this paper illustrates that ilmenite is the main source of titanium and details different metallurgic processes for producing titanium and titanium alloys. The energy consumption required for each production step is also illustrated. An overview of additive manufacturing techniques is provided, along with an analysis of their relative challenges. The main focus of the review is on the current technologies employed for the recycling of swarf. Literature suggests that the most promising ways are the technologies based on severe plastic deformation, such as equal-channel angular pressing, solid-state field-assisted sintering technology-forge, and the Conform process. The latter is becoming established in the field and can replace the actual production of conventional titanium wire. Titanium-recycled powder for additive manufacturing is mainly produced using gas atomization techniques.

show abstract

Oxidation induced mechanisms during directed energy deposition additive manufactured titanium alloy builds

Cited by 13 publications

References 57 publications

Mitigation of Gas Porosity in Additive Manufacturing Using Experimental Data Analysis and Mechanistic Modeling

Mitigation of Gas Porosity in Additive Manufacturing Using Experimental Data Analysis and Mechanistic Modeling

Additive Manufacturing of Titanium Alloys: Processability, Properties, and Applications

Sustainable Recovery of Titanium Alloy: From Waste to Feedstock for Additive Manufacturing

Contact Info

Product

Resources

About