Study on the influence of process parameters on high performance Ti-6Al-4V parts in laser powder bed fusion

Wang, Peng; Chen, Dongju; Fan, Jinwei; Sun, Kun; Wu, Shuiyuan; Li, Jia; Sun, Yueqiang

doi:10.1108/rpj-09-2021-0235

Cited by 8 publications

(4 citation statements)

References 53 publications

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“…and they result in mechanical properties similar to conventional manufacturing technologies (Mercelis and Kruth, 2006; Caulfield, Mchugh and Lohfeld, 2007; S. Azar et al , 2021; Sadeghi and Mohseni, 2022; Wang et al , 2022; Mohseni et al , 2023).…”

Section: Introductionmentioning

confidence: 96%

Design for additive manufacturing of topology-optimized structures based on deep learning and transfer learning

Mohseni,

Khodaygan

2024

RPJ

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Purpose This paper aims to improve the manufacturability of additive manufacturing (AM) for topology-optimized (TO) structures. Enhancement of manufacturability focuses on modifying geometric constraints and classifying the building orientation (BO) of AM parts to reduce stresses and support structures (SSs). To this end, artificial intelligence (AI) networks are being developed to automate design for additive manufacturing (DfAM). Design/methodology/approach This study considers three geometric constraints for their correction by convolutional autoencoders (CAEs) and transfer learning (TL). Furthermore, BOs of AM parts are classified using generative adversarial (GAN) and classification networks to reduce the SS. To verify the results, finite element analysis (FEA) is performed to compare the stresses of modified components with the original ones. Moreover, one sample is produced by the laser-based powder bed fusion (LB-PBF) in the BO predicted by the AI to observe its SSs. Findings CAE and TL resulted in promoting the manufacturability of TO components. FEA demonstrated that enhancing manufacturability leads to a 50% reduction in stresses. Additionally, training GAN and pre-training the ResNet-18 resulted in 80%, 95% and 96% accuracy for training, validation and testing. The production of a sample with LB-PBF demonstrated that the predicted BO by ResNet-18 does not require SSs. Originality/value This paper provides an automatic platform for DfAM of TO parts. Consequently, complex TO parts can be designed most feasibly and manufactured by AM technologies with minimal material usage, residual stresses and distortions.

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Section: Introductionmentioning

confidence: 96%

Design for additive manufacturing of topology-optimized structures based on deep learning and transfer learning

Mohseni,

Khodaygan

2024

RPJ

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“…A superalloy is a kind of high-temperature resistant metal material composed of Ni, Co, and other elements. Due to its good oxidation resistance, corrosion resistance, and excellent strength at high temperatures, it is often used in equipment such as aero-engine and industrial gas turbines [2]. GH99, a typical aging strengthening nickel-base superalloy, is mainly used in high-temperature structural materials such as aerospace turbines and power station turbines.…”

Section: Introductionmentioning

confidence: 99%

Microstructural Evolution and Mechanical Properties of Ti2AlNb/GH99 Superalloy Brazed Joints Using TiZrCuNi Amorphous Filler Alloy

Cai

Liu

et al. 2023

Aerospace

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Dissimilar materials brazing of Ti2AlNb alloy to GH99 superalloy is of great pragmatic importance in the aerospace field, especially the lightweight space aircraft components manufacturing. In this work, TiZrCuNi amorphous filler alloy was used as brazing filler, and experiments were carried out at different brazing temperatures and times to investigate the changes in interfacial structures and properties of the joints. The typical interfacial microstructure was Ti2AlNb alloy/B2/β/Ti2Ni (Al, Nb) + B2/β + (Ti, Zr)2(Ni, Cu) + (Ti, Zr)(Ni, Cu)/(Cr, Ni, Ti) solid solution + (Ni, Cr) solid solution/GH99 superalloy when being brazed at 1000 °C for 8 min. The interfacial microstructure of the joints was influenced by diffusion and reaction between the filler alloy and the parent metal. The prolongation of brazing process parameters accelerated the diffusion and reaction of the liquid brazing alloy into both parent metals, which eventually led to the aggregation of (Ti, Zr)2(Ni, Cu) brittle phase and increased thickness of Ti2Ni (Al, Nb) layer. According to fracture analyses, cracks began in the Ti2Ni (Al, Nb) phase and spread with it as well as the (Ti, Zr)2(Ni, Cu) phase. The joints that were brazed at 1000 °C for 8 min had a maximum shear strength of ~216.2 MPa. Furthermore, increasing the brazing temperature or extending the holding time decreased the shear strength due to the coarse Ti2Ni (Al, Nb) phase and the continuous (Ti, Zr)2(Ni, Cu) phase.

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“…Choy, Sing Ying, et al [ 12 ] produced strut-based and honeycomb lattice structures by L-PBF processing and found that abrupt shear failure took place at the opposite corners of the lattice samples during compression testing since the diagonal struts in the planar section were oriented parallel to the compression direction. Additionally, the authors in reference [ 13 ] employed an experimental approach to find the processing conditions that can fabricate high-performance Ti6Al4V parts using the L-PBF process.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Properties of Titanium/Nano-Fluorapatite Parts Produced by Laser Powder Bed Fusion

Lin

Jiang

et al. 2023

Materials

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Laser powder bed fusion (L-PBF) has attracted great interest in recent years due to its ability to produce intricate parts beyond the capabilities of traditional manufacturing processes. L-PBF processed biomedical implants are usually made of commercial pure titanium (CP-Ti) or its alloys. However, both alloys are naturally bio-inert, and thus reduce the formation of apatite as implants are put into the human body. Accordingly, in an attempt to improve the bioactivity of the materials used for making orthopedic implants, the present study decomposed fluorapatite material (FA, (Ca10(PO4)6F2)) into the form of nano-powder and mixed this powder with CP-Ti powder in two different ratios (99%Ti + 1%FA (Ti-1%FA) and 98%Ti + 2%FA (Ti-2%FA)) to form powder material for the L-PBF process. Experimental trials were conducted to establish the optimal processing conditions (i.e., laser power, scanning speed and hatching space) of the L-PBF process for the two powder mixtures and the original CP-Ti powder with no FA addition. The optimal parameters were then used to produce tensile test specimens in order to evaluate the mechanical properties of the different samples. The hardness of the various samples was also examined by micro-Vickers hardness tests. The tensile strength of the Ti-1%FA sample (850 MPa) was found to be far higher than that of the CP-Ti sample (513 MPa). Furthermore, the yield strength of the Ti-1%FA sample (785 MPa) was also much higher than that of the CP-Ti sample (472 MPa). However, the elongation of the Ti-1%FA sample (6.27 %) was significantly lower than that of the CP-Ti sample (16.17%). Finally, the hardness values of the Ti-1%FA and Ti-2%FA samples were around 63.8% and 109.4%, respectively, higher than that of the CP-Ti sample.

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Study on the influence of process parameters on high performance Ti-6Al-4V parts in laser powder bed fusion

Cited by 8 publications

References 53 publications

Design for additive manufacturing of topology-optimized structures based on deep learning and transfer learning

Design for additive manufacturing of topology-optimized structures based on deep learning and transfer learning

Microstructural Evolution and Mechanical Properties of Ti2AlNb/GH99 Superalloy Brazed Joints Using TiZrCuNi Amorphous Filler Alloy

Mechanical Properties of Titanium/Nano-Fluorapatite Parts Produced by Laser Powder Bed Fusion

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