Solid-state additive manufacturing of tantalum using high-pressure cold gas-dynamic spray

Jafarlou, Davoud M.; Sousa, Bryer C.; Gleason, Matthew A.; Ferguson, Gehn; Nardi, Aaron; Cote, Danielle L.; Grosse, Ian R.

doi:10.1016/j.addma.2021.102243

Cited by 14 publications

(8 citation statements)

References 50 publications

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“…The tantalum printed parts had an average hardness value of 265.97 ± 2.34 HV surpassing the hardness of EBM Ta (110 HV) and powder metallurgy compacted Ta (120 HV). 102 Additionally, parts processed by the cold spray techniques have been investigated for corrosion resistance. [93][94][95] This property is especially crucial for refractory metals used in high-performance applications such as aerospace, nuclear energy and defence, as corrosion can compromise the integrity of the part and potentially lead to catastrophic failures.…”

Section: Non-melt-based Additive Manufacturingmentioning

confidence: 99%

Additive manufacturing of refractory metals and carbides for extreme environments: an overview

Mukherjee,

Gabourel,

Firdosy

et al. 2024

Science and Technology of Welding and Joining

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Refractory metals and their carbides possess extraordinary properties when subjected to high temperatures and extreme environments. Consequently, they can act as key material systems for advancing many sectors, including space, energy and defence. However, it has been difficult to process these materials using the conventional routes of manufacturing. Additive manufacturing (AM) has shown a lot of potential to overcome the challenges and develop new material systems with tailored properties. This review provides a fundamental understanding of the challenges in the processing of refractory metals and their carbides, including microcracking, formation of brittle oxide phases and high ductile to brittle transition temperature (DBTT). We also highlight some of the novel approaches that have been taken to improve the processability of these challenging material systems using AM. These include in-situ reactive printing, ultrasonic vibration, laser beam shaping, multi-laser deposition and substrate pre-heating with a focus on microstructural changes to improve the properties of printed parts.

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Section: Non-melt-based Additive Manufacturingmentioning

confidence: 99%

Additive manufacturing of refractory metals and carbides for extreme environments: an overview

Mukherjee,

Gabourel,

Firdosy

et al. 2024

Science and Technology of Welding and Joining

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“…The modulus of elasticity values vs. hardness values for all 10,000 data points presented in (a-c) are plotted as the y-axis and x-axis shown in (d). For further details surrounding nanomechanical property mapping and data analysis (in terms of both theory and practice), please see [31].…”

Section: Sample Characterizationmentioning

confidence: 99%

Microstructural, Corrosion, and Mechanical Characterization of Friction Stir Welded Al 6022-to-ZEK100 Mg Joints

Ding

Das

Upadhyay

et al. 2023

CMD

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Friction stir welded (FSW) aluminum–magnesium lightweight vehicle joints have gained significant interest due to their high strength-to-weight ratio. In this work, the corrosion resistance of this material is analyzed through electrochemical tests, which include open circuit potential (OCP) inspection and potentiodynamic polarization (PD) scanning. Weight loss measurements tested the corrosion rate of the FSW weld through cyclic corrosion testing (CCT) according to the standard SAEJ 2334. Mechanical properties were also investigated, including lap-shear strength, micro- and nano-hardness mapping, and true stress–strain curves as a function of local processing history. The electrochemical results indicate that the center weld zone’s corrosion property stays between the two base alloys. Indentation-based testing demonstrated that the weld zone behaves differently from base alloys. Lap shear strength surprisingly did not drop much even after eight weeks of cyclic corrosion tests, indicating that the joint did not allow any ingress of the electrolyte.

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“…Figure 5 (c) shows a SEM image of the surface of the Ta(CS) sample after mechanical polishing to the mirror-like surface finish (roughness <0.5 μ m) featuring the Ta surface (bright contrast) and a stainless steel particle surface (dark contrast) embedded in the coating. The small black dots and striations on the Ta regions highlighted with the blue line are likely micropores in the Ta coating and the region encircled in red highlights the slightly separated particle-to-particle interface [10]. These defects could have originated in the coating surface produced during the sample preparation procedures.…”

Section: Effects Of D Irradiation and Annealing Tests 321 Microstruct...mentioning

confidence: 99%

“…For example, the recent work by Neu et al [8] reported the successful deposition of thick mixed tungsten/tantalum coatings capable of withstanding fusion-relevant heat transients (up to 4 MW m −2 ), suggesting cold spray to be a promising technology for fusion applications. Tantalum (Ta) is a widely used material in chemistry, medical applications, electronics, aerospace and nuclear industry [9] because of its high melting temperature, excellent room-temperature ductility [10] and outstanding corrosion resistance [5,11]. Ta, similar to titanium (Ti), exhibits exothermic hydrogen absorption which results in a much higher hydrogen isotopes (HIs) inventory compared to other refractory metals such as tungsten (W) and molybdenum (Mo) [12][13][14].…”

Section: Introductionmentioning

confidence: 99%

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Initial study on thermal stability of cold spray tantalum coating irradiated with deuterium for fusion applications

Ialovega,

Dabney,

Navarro Gonzalez

et al. 2023

Phys. Scr.

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Removal of neutral hydrogen atoms in the plasma edge reduces the number of charge exchange events and thus, the net energy losses in the plasma, significantly improving performance of fusion devices. Effective control of the residual pressure of hydrogen isotopes (HIs) in the plasma edge may be achieved by utilizing a hydrogen absorbing first wall interface capable of withstanding the harsh fusion environment. In this study, we have investigated tantalum (Ta) coating deposited by cold spray technology on 316L stainless steel substrate as a potential plasma-facing material surface. High fluence low energy deuterium plasma irradiation experiments and subsequent thermal annealing cycles associated with thermal desorption spectrometry (TDS) demonstrated superior structural stability of the Ta coating. TDS experiments revealed the outgassing of deuterium (as measure of its retention) for cold spray Ta coatings to be three times higher than bulk Ta and two orders of magnitude greater than bulk polycrystalline W. X-ray photoelectron spectroscopy revealed evolution of oxidation states upon deuterium irradiation and a partial recovery of the metallic signature of Ta after the thermal treatment at 1100 K.

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Solid-state additive manufacturing of tantalum using high-pressure cold gas-dynamic spray

Cited by 14 publications

References 50 publications

Additive manufacturing of refractory metals and carbides for extreme environments: an overview

Additive manufacturing of refractory metals and carbides for extreme environments: an overview

Microstructural, Corrosion, and Mechanical Characterization of Friction Stir Welded Al 6022-to-ZEK100 Mg Joints

Initial study on thermal stability of cold spray tantalum coating irradiated with deuterium for fusion applications

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