Rapid Alloy Development of Extremely High-Alloyed Metals Using Powder Blends in Laser Powder Bed Fusion

Ewald, Simon; Kies, Fabian; Hermsen, Steffen; Voshage, Maximilian; Haase, Christian; Schleifenbaum, Johannes Henrich

doi:10.3390/ma12101706

Cited by 56 publications

(30 citation statements)

References 39 publications

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“…MMnS-medium-manganese steel [42], SRIP-slip-band refinement-induced plasticity [43], TRIP-transformation-induced plasticity, TWIP-twinning-induced plasticity [44], ECAP-equal-channel angular pressing [45], SLM-selective laser melting [46]. Indeed, several of the approaches presented in Figure 8 have already been transferred to HEAs, such as TRIP and TWIP effects [17,47], precipitation hardening in compositionally complex alloys (CCAs) [48], recovery annealing [8], severe plastic deformation [49], additive manufacturing [50], etc. However, the further maturity of thermodynamics-based [51,52] and ab initio methods are required to explore the wide composition space of HEAs and CCAs.…”

Section: Mechanism-oriented Alloy Designmentioning

confidence: 99%

From High-Manganese Steels to Advanced High-Entropy Alloys

Haase

Barrales‐Mora

2019

Metals

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Arguably, steels are the most important structural material, even to this day. Numerous design concepts have been developed to create and/or tailor new steels suited to the most varied applications. High-manganese steels (HMnS) stand out for their excellent mechanical properties and their capacity to make use of a variety of physical mechanisms to tailor their microstructure, and thus their properties. With this in mind, in this contribution, we explore the possibility of extending the alloy design concepts that haven been used successfully in HMnS to the recently introduced high-entropy alloys (HEA). To this aim, one HMnS steel and the classical HEA Cantor alloy were subjected to cold rolling and heat treatment. The evolution of the microstructure and texture during the processing of the alloys and the resulting properties were characterized and studied. Based on these results, the physical mechanisms active in the investigated HMnS and HEA were identified and discussed. The results evidenced a substantial transferability of the design concepts and more importantly, they hint at a larger potential for microstructure and property tailoring in the HEA. several core effects (high-entropy effect, sever lattice distortion effect, sluggish diffusion effect, cocktail effect) of HEAs have been proposed [5], a clear design strategy is still missing.The underlying physical mechanisms active in HMnS have already been studied for several decades [1,2,6], and therefore are comparatively well understood. One of the most important parameters when designing HMnS is the tailoring of their stacking fault energy (SFE). This property controls the dissociation distance of partial dislocations and determines whether TRIP and/or TWIP is activated/suppressed during plastic deformation. The role of the SFE during plastic deformation and subsequent heat treatment in metals has been studied for decades, and its effect is relatively well-known for face-centered cubic (fcc) metals [7]. In fcc HEAs, the mechanisms of microstructure formation have been found to occur in a similar way to the same class of alloys with comparable SFE [8]. For instance, the Cantor alloy (CoCrFeMnNi) with an estimated SFE between 18.3-27.3 mJ/m 2 [9,10] has been shown to develop the TWIP effect, depending on the processing conditions [11]. Evidently, the determination of the SFE in HEAs is fundamental, because this property indicates the possible acting mechanisms for microstructure development. However, as with steels, the complex chemistry of HEAs leads to almost unlimited combinations that make a systematic determination of this property difficult. Nevertheless, to accelerate the development of these alloys, several research groups have made use of ab initio calculations, e.g., [12]. The advantage of this method is that it is possible to calculate several alloy compositions with less effort than the one required for an experimental determination of the same alloys. So far, the systems CoCrFeMnNi [9,10,13,14], AlCoCrCuFeNi, and AlCoCrFeNi [15] have been investig...

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Section: Mechanism-oriented Alloy Designmentioning

confidence: 99%

From High-Manganese Steels to Advanced High-Entropy Alloys

Haase

Barrales‐Mora

2019

Metals

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“…Cylindrical samples were manufactured on an Aconity MINI LPBF machine by Aconity3D using elemental powder blends. This method can be reliably used to generate fully dense samples without macro-segregation and only minor, regularly distributed micro-segregation, as previously shown in [16] . These were generated with 200 W laser power, 550 mm s −1 scanning speed, 60 μm hatch distance and 30 μm layer thickness for equiatomic CoFeMnNi samples with 3 wt% Al and 0, 0.3 and 0.6 wt% C ( Table 1 ).…”

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confidence: 66%

“…However, the number of possible elemental combinations of MPEAs makes tailoring of individual properties challenging, as it requires powerful screening methods to efficiently explore the alloying space [12,13] . Previously, we suggested a methodology combining thermodynamic modeling with additive manufacturing (AM) using elemental powder blends [14][15][16] to rapidly screen MPEAs. A new calphad database was compiled from all binary and available ternary systems of CoCrFeMnNi, which largely do not contain hexagonally closest packed (hcp) phases.…”

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“…temperature, grain size and strain rate remained constant, a decrease in SFE must have been responsible for this behavior. Due to the same processing parameters, the amount and amplitude of micro-segregation [16] is equal in the samples with varying chemical composition. These micro-segregations are very small in LPBF-produced metals in contrast to laser metal deposition [15,66] .…”

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Combined Al and C alloying enables mechanism-oriented design of multi-principal element alloys: Ab initio calculations and experiments

et al. 2020

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Density functional theory (DFT) calculations were performed on Al x C y CoFeMnNi multi-principal element alloys (MPEAs) to understand the influence of Al and C on the stacking-fault energy (SFE). C addition to CoFeMnNi resulted in increased SFE, while it decreased in Al-alloyed CoFeMnNi. For experimental verification, Al 0.26 C y CoFeMnNi with 0, 1.37 and 2.70 at% C were designed by computational thermodynamics, produced by additive manufacturing (AM) and characterized by tensile tests and microstructure analysis. Twinning-induced plasticity (TWIP) was enhanced with increased C, which confirmed a decreased SFE. The combination of these methods provides a promising toolset for mechanism-oriented design of MPEAs with advanced mechanical properties.

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“…In addition, a similar methodology has also been successfully employed and validated for high-entropy alloys. [58][59][60][61][62][63][64][65]…”

Section: Alloy Selectionmentioning

confidence: 99%

Optimal Design for Metal Additive Manufacturing: An Integrated Computational Materials Engineering (ICME) Approach

Motaman

Kies

Köhnen

et al. 2020

JOM

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We present our latest results on linking the process-structure-propertiesperformance (PSPP) chain for metal additive manufacturing (AM), using a multi-scale and multi-physics integrated computational materials engineering (ICME) approach. The abundance of design parameters and the complex relationship between those and the performance of AM parts have so far impeded the widespread adoption of metal AM technologies for structurally critical load-bearing components. To unfold the full potential of metal AM, establishing a full quantitative PSPP linkage is essential. It will not only help in understanding the underlying physics but will also serve as a powerful and effective tool for optimal computational design. In this work, we illustrate an example of ICME-based PSPP linkage in metal AM, along with a hybrid physics-based data-driven strategy for its application in the optimal design of a component. Finally, we discuss our outlook for the improvement of each part in the computational linking of the PSPP chain.

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Rapid Alloy Development of Extremely High-Alloyed Metals Using Powder Blends in Laser Powder Bed Fusion

Cited by 56 publications

References 39 publications

From High-Manganese Steels to Advanced High-Entropy Alloys

From High-Manganese Steels to Advanced High-Entropy Alloys

Combined Al and C alloying enables mechanism-oriented design of multi-principal element alloys: Ab initio calculations and experiments

Optimal Design for Metal Additive Manufacturing: An Integrated Computational Materials Engineering (ICME) Approach

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