Role of deposition strategy and fill depth on the tensile and fatigue performance of 300 M repaired through laser directed energy deposition

Barr, Cameron; Rashid, Rizwan Abdul Rahman; Sun, Shoujin; Easton, Mark; Palanisamy, Suresh; Orchowski, Nicholas; Matthews, Neil; Walker, K.; Brandt, Milan

doi:10.1016/j.ijfatigue.2020.106135

Cited by 23 publications

(19 citation statements)

References 44 publications

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“…Despite this, their appearance in the fracture surfaces suggest they can have a significant deleterious effect on mechanical behaviour. Finally, very fine pores (<1μm) were also found with both shielding types, but do not appear to have a [16], with the worst performance linked to large gas pores that are eliminated with chamber shielding. Unmelted powder defects are still problematic for chamber shielding.…”

Section: Resultsmentioning

confidence: 94%

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Effect of oxygen shielding on the tensile and fatigue performance of 300M repaired through laser-directed energy deposition

Barr,

Rashid,

Palanisamy

et al. 2023

Aeronaut. j.

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Laser-directed energy deposition (L-DED) is a key enabling technology for the repair of high-value aerospace components, as damaged regions can be removed and replaced with additively deposited material. While L-DED repair improves strength and fatigue performance compared to conventional subtractive techniques, mechanical performance can be limited by process-related defects. To assess the role of oxygen on defect formation, local and chamber-based shielding methods were applied in the repair of 300M high strength steel. Oxidation between layers for locally shielded specimens is confirmed to cause large gas pores which have deleterious effects on fatigue life. Such pores are eliminated for chamber shielded specimens, resulting in an increased ductility of ∼15%, compared to ∼11% with chamber shielding. Despite this, unmelted powder defects are not affected by oxygen content and are found in both chamber- and locally shielded samples, which still have negative consequences for fatigue.

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Section: Resultsmentioning

confidence: 94%

“…Figure 5. Influence of defects on the fatigue performance for locally shielded 300M/300M repairs[16], with the worst performance linked to large gas pores that are eliminated with chamber shielding. Unmelted powder defects are still problematic for chamber shielding.…”

mentioning

confidence: 99%

Effect of oxygen shielding on the tensile and fatigue performance of 300M repaired through laser-directed energy deposition

Barr,

Rashid,

Palanisamy

et al. 2023

Aeronaut. j.

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“…Extending a component's life cycle is attractive from both an economic perspective, as large components such as casting dies are expensive to produce [29], but also from an environmental perspective, as it leads to less material waste. Recent research focused on using DED as a repairing tool includes the study of deposition strategy and fill depth in component properties by C. Barr et al [30], which studied the monotonic and fatigue behaviour of several specimens with distinct percentages of added 18Ni300 material, analysing the intergranular cracking as the main crack initiation mechanism. J. Bennet et al [31] studied the mechanical reliability and enviornmental impact of repairing an automotive die through DED using H13, inferring a better performance than conventional TIG welding repair as the DED-remanufactured die achieved the same life as the original die.…”

Section: Introductionmentioning

confidence: 99%

“…Maraging steels' use within die repairing via DED is justified by its mechanical strength, acceptable corrosion resistance [30] and good weldability [23]. Nevertheless, it is necessary to understand its properties after DED processing, as well as evaluate the adhesion between printed geometries and the substrate.…”

Section: Introductionmentioning

confidence: 99%

Tensile Properties of As-Built 18Ni300 Maraging Steel Produced by DED

et al. 2022

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The mechanical behaviour of as-built DED-produced 18Ni300 Maraging steel was studied by manufacturing a wall-like structure from which three different specimen types were obtained: specimens in which the loading direction was the same as the printing direction (vertical), specimens in which these two directions were perpendicular (horizontal), and bimetallic specimens in which the interface between the AISI 1045 substrate and the 18Ni300 steel was tested. The yield strength of the produced samples was 987.9±34.2, 925.9±89.7 and 486.7±47.2MPa for the vertical, horizontal and bimetallic specimens, respectively, while the elongation to failure was 9.4±1.9, 18.3±2.3 and 14.06±0.6% in the same order. The latter specimen failed within the substrate-comprised portion of the specimen. Additionally, the fracture surfaces were analysed through scanning electron microscopy, concluding that while both surfaces consist of dimples, the horizontal specimen presented microporosities with a reduced diameter. A microhardness analysis in the printed wall-like structure following the printing direction yielded an average hardness of 392±21 HV0.3, with fluctuations along the build direction mostly within one standard deviation.

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“…The hardness profile across the cladded regions of the as-deposited sample indicated the presence of hard (>650 HV) untempered martensite in both the clad and the heat-affected zone, whereas the hardness in the heat-affected zone decreased to about 500-590 HV after the laser post-heat treatment. Cameron et al [31] studied the roles of deposition strategy and fill depth in the tensile properties of 300 M repaired through laser-directed energy deposition. The ultimate tensile strength was 1902 MPa for the 300M specimen repaired with the 10% effective repair depth via the track delay deposition strategy, whereas the ultimate tensile strength was reduced to 1560 MPa by the layer delay deposition strategy repaired with the 100% effective repair depth.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Microstructure and Mechanical Properties of an Ultrahigh Strength Martensitic Steel Fabricated Using Laser Metal Deposition Additive Manufacturing

Wang

Zhang

et al. 2022

Metals

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Ultrahigh strength steels were additively manufactured (AM) using different batches of powders by means of the laser metal deposition (LMD) technique. After quenching and tempering treatments, the microstructures, mechanical properties, and fracture modes of ultrahigh strength steels were investigated by several testing methods. The results demonstrate that martensite and Fe3C cementite were found in the three specimens after quenching and tempering treatments, and the tempered martensite microstructure had a lamellar structure in all specimens. The widths of these martensite lathes were observed to be different for the APHT-1, APHT-2, and APHT-3 samples, and their sizes were 1.92 ± 0.90 μm, 1.87 ± 1.09 μm, and 1.82 ± 0.85 μm, respectively. The martensitic steel exhibited excellent mechanical properties (tensile strength and impact toughness). The yield strength and the ultimate tensile strength of the APHT-3 sample reached 1582 MPa and 1779 MPa, respectively. Moreover, the value of the impact energy for the APHT-1 sample was 46.4 J. In addition, with the changes in the batches of ultrahigh strength steel powders, the fracture mode changed from ductile fracture to brittle fracture under tensile force and impact loads.

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Role of deposition strategy and fill depth on the tensile and fatigue performance of 300 M repaired through laser directed energy deposition

Cited by 23 publications

References 44 publications

Effect of oxygen shielding on the tensile and fatigue performance of 300M repaired through laser-directed energy deposition

Effect of oxygen shielding on the tensile and fatigue performance of 300M repaired through laser-directed energy deposition

Tensile Properties of As-Built 18Ni300 Maraging Steel Produced by DED

Investigation of the Microstructure and Mechanical Properties of an Ultrahigh Strength Martensitic Steel Fabricated Using Laser Metal Deposition Additive Manufacturing

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