Effect of process parameters on the metallurgical characteristics of additive-manufactured alloys

• Grant number: 17/27031-4
• Support Opportunities: Research Grants - Young Investigators Grants
• Duration: December 01, 2018 - November 30, 2023
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Physical Metallurgy
• Principal Investigator: Piter Gargarella
• Grantee: Piter Gargarella
• Host Institution: Centro de Ciências Exatas e de Tecnologia (CCET). Universidade Federal de São Carlos (UFSCAR). São Carlos , SP, Brazil
• Associated researchers: Claudemiro Bolfarini ; Claudio Shyinti Kiminami ; Guilherme Yuuki Koga ; Nelson Guedes de Alcântara
• Associated grant(s): 19/03891-0 - Equipment for additive manufacturing of metals, AP.EMU
• Associated scholarship(s): 22/15435-1 - Fracture toughness of quasicrystalline phase-former aluminum alloy fabricated by additive manufacturing, BP.MS; 22/15683-5 - Study of the influence of particle size distribution and moisture on the flowability of aluminum alloy powder through numerical modeling, BP.IC; 22/08457-9 - Austenitic stainless steels imparied by sulfides and carbides: Surface recovery by LASER remelting, BP.MS; + associated scholarships 22/05528-2 - Additive Manufacturing of layered metal composites with soft magnetic properties, BP.DR; 22/15072-6 - Study of energy density equations used in Laser Powder Bed Fusion, BP.IC; 22/12178-8 - Fabrication and characterization of Fe-Si6.5 soft magnetic alloy metallic powders produced via gas atomization, BP.IC; 21/10651-5 - Characterization of cold spray coatings of a quasicrystal-forming Al-Fe-Cr-Ti alloy, BP.IC; 21/11934-0 - Additive manufacturing of Fe77Mo5P9C7.5B1.5 glass former alloy, BP.IC; 21/12091-7 - Effect of particle size distribution and drying treatment on the flowability of 2017 aluminum alloy powder, BP.IC; 21/10440-4 - Wear behavior of Al-Fe-Cr-Ti alloy processed by additive manufacturing, BP.IC; 20/09544-7 - Surface functionalization of AA2017 powder for additive manufacturing, BP.DR; 20/09343-1 - Effect of processing parameters in the additive manufacturing of A2 tool steel, BP.DD; 20/04418-3 - Technical support in the atomization and coatings lab of DEMa/UFSCar, BP.TT; 20/08145-1 - Gas atomization of 2017 aluminum alloy, BP.MS; 20/04366-3 - Technical support in the LASER Materials Processing Lab of DEMa/UFSCar, BP.TT; 20/01426-5 - Effect of processing parameters on microstruture and mechanical properties of aluminum alloys obtained by additive manufacturing, BP.DD; 20/01452-6 - Effect of processing parameters on the properties of gas atomized powders of A2 tool steel, BP.MS; 19/12705-5 - Characterization of 2017 aluminum alloy samples produced by additive manufacturing, BP.IC; 19/12712-1 - Characterization of A2 tool steel samples produced by additive manufacturing, BP.IC - associated scholarships

Abstract

The production of metallic parts layer by layer, well-known as Additive Manufacturing (AM), has increased the flexibility and freedom to design metallic products. This area undergone a huge development in the last years thanks to the possibility to produce near-net-shape components, with customized density and complex shapes (sometimes impossible to achieve with traditional manufacturing methods) and to the development of new AM technologies with competitive prices. Products fabricated by AM are already in use in the aeronautic, automotive and biomedical industries. To make use of all the AM potential, it is necessary to develop new alloys specifically for these processes, as was done in the past by the casting and forming industries, to adjust the solidification mode to the thermal characteristics of AM. Several challenges still exist with use of the available metallic alloys as the formation of macro and micro defects during build up, residual stresses generated during process, composition control during melting, formation of texture and hot tears, formation of microstructural heterogeneities, among others. Most of these defects occur because the alloy composition is not adequate for the AM process. The products obtained must satisfy specifications of composition, surface quality, damage tolerance, fatigue, strength and other properties, which are very sensitive to changes in composition and/or microstructure and defects fraction. Nowadays, only a few additive manufacturing alloys as AlSi10Mg, TiAl6V4, CoCr and Inconel 718 can be used in critical applications where high strength and good fatigue and toughness properties are required. Most of the 5500 alloys available today cannot be used because the melting and solidification dynamics promote the formation of long cellular/dendritic grains with cracks periodically distributed in the material. Taking this into consideration, this project aims to investigate the effect of processing parameters in the metallurgical characteristics of parts produced by AM, trying to understand how these parameters affect the solidification behaviour and thermal flow during processing. Two alloys were chosen for this investigation: tool steel AISI A2 and aluminum alloy A2017. Powders will be obtained by gas atomization and it will be used to produce parts by the additive manufacturing processes of Powder Bed Fusion (PBF) e Directed Energy Deposition (DED). It will be investigated the influence of scanning speed, laser power, hatching, scanning strategy and powder characteristics (with and without additions of nucleant particles) in the metallurgical behaviour of the samples obtained. These samples will be characterized by X-ray Diffraction, Differential Scanning Calorimetry, Optical Microscopy, Scanning Electron Microscopy and Transmission Electron Microscopy, Computer X-ray Tomography, chemical analyses, tensile, hardness, fatigue and toughness tests. Simulations of phase formation and solidification by THERMOCALC and numerical modeling of the heat flow will be carried out and compared with the experimental results. The processing parameters used will be correlated with the microstructure, phase formation and properties of the AM samples. (AU)

Scientific publications

(21)

(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)

BATALHA, RODOLFO LISBOA; PAULY, SIMON; KUHN, UTA; KOSIBA, KONRAD; BOLFARINI, C.; KIMINAMI, CLAUDIO SHYINTI; GARGARELLA, PITER. Oligocrystalline microstructure in an additively manufactured biocompatible Ti-Nb-Zr-Ta alloy. Materials Letters, v. 262, MAR 1 2020. (17/27031-4, 13/05987-8)

RICCARDO AUGUSTO MOREIRA MONTUORI; GUSTAVO FIGUEIRA; THIAGO PACAGNAN CATALDI; NELSON GUEDES DE ALCÂNTARA; CLAUDEMIRO BOLFARINI; REGINALDO TEIXEIRA COELHO; PITER GARGARELLA. Manufatura Aditiva de Aço Inoxidável 316L por Fusão Seletiva a Laser. Soldagem & Inspeção, v. 25, 2020-09-28. (17/27031-4, 16/11309-0, 19/01829-5, 18/16898-0, 18/06691-9)

BATALHA, RODOLFO LISBOA; BATALHA, WEVERSON CAPUTE; DENG, LIANG; GUSTMANN, TOBIAS; PAULY, SIMON; KIMINAMI, CLAUDIO SHYINTI; GARGARELLA, PITER. Processing a biocompatible Ti-35Nb-7Zr-5Ta alloy by selective laser melting. Journal of Materials Research, v. 35, n. 9, p. 1143-1153, MAY 14 2020. (17/27031-4, 13/05987-8)

GERA, DENNIS; SANTOS, JONADABE; KIMINAMI, CLAUDIO S.; GARGARELLA, PITER. Comparison of Cu-Al-Ni-Mn-Zr shape memory alloy prepared by selective laser melting and conventional powder metallurgy. TRANSACTIONS OF NONFERROUS METALS SOCIETY OF CHINA, v. 30, n. 12, p. 3322-3332, DEC 2020. (17/27031-4, 13/05987-8, 16/00583-4)

MAZZER, E. M.; DA SILVA, M. R.; GARGARELLA, P.. evisiting Cu-based shape memory alloys: Recent developments and new perspective. Journal of Materials Research, v. 37, n. 1, SI, p. 162-182, JAN 14 2022. (13/05987-8, 17/27031-4)

BATALHA, RODOLFO LISBOA; PINOTTI, VITOR EDUARDO; ALNOAIMY, OMAR O. S.; BATALHA, WEVERSON CAPUTE; GUSTMANN, TOBIAS; KOSIBA, KONRAD; PAULY, SIMON; BOLFARINI, CLAUDEMIRO; KIMINAMI, CLAUDIO SHYINTI; GARGARELLA, PITER. icrostructure and properties of TiB2-reinforced Ti-35Nb-7Zr 5Ta processed by laser-powder bed fusio. Journal of Materials Research, v. 37, n. 1, SI, p. 259-271, JAN 14 2022. (13/05987-8, 17/27031-4)

DE ARAUJO, AYLANNA P. M.; KIMINAMI, CLAUDIO S.; UHLENWINKEL, VOLKER; GARGARELLA, PITER. Processability of recycled quasicrystalline Al-Fe-Cr-Ti composites by selective laser melting- A statistical approach. MATERIALIA, v. 22, p. 23-pg., 2022-03-03. (18/04209-5, 17/27031-4, 16/11309-0)

DE ARAUJO, AYLANNA P. M.; KIMINAMI, CLAUDIO S.; UHLENWINKEL, VOLKER; GARGARELLA, PITER. High-temperature tensile properties of an aluminum quasicrystal-forming alloy manufactured by laser powder bed fusion. MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING, v. 886, p. 10-pg., 2023-10-17. (13/05987-8, 17/27031-4, 18/04209-5)

MAZZER, E. M.; DA SILVA, M. R.; GARGARELLA, P.. evisiting Cu-based shape memory alloys: Recent developments and new perspective. Journal of Materials Research, JAN 2022. (17/27031-4, 13/05987-8)

BOMFIM, PAMELA KARINA DOS SANTOS; COURY, FRANCISCO GIL; WANG, PEI; GARGARELLA, PITER. Characterization of AlCoCrFeNi High Entropy Alloy Gas Atomized Powder. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 25, n. 1, 2022. (17/27031-4)

PEDRO HENRIQUE EÇA RODRIGUES; LUIZ FERNANDO KULTZ UNTI; FÁBIO EDSON MARIANI; PITER GARGARELLA; OSVALDO MITSUYUKI CINTHO; ANTONIO J. RAMIREZ; KAHL ZILNYK. Effect of Hot Isostatic Pressing of Water Atomized AISI 316L Manufactured by Laser Powder Bed Fusion. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 26, 2023-05-26. (19/06679-1, 17/27031-4)

MATHIAS, LAURA E. T.; ANDREOLI, ANGELO F.; GARGARELLA, PITER. Gas atomization of A2 tool steel: Effect of process parameters on powders' physical properties. Journal of Alloys and Compounds, v. 960, p. 9-pg., 2023-06-04. (17/27031-4, 21/12056-7)

CANEDA, CHAIANE M.; GARGARELLA, PITER; RIVA, RUDIMAR; KIMINAMI, CLAUDIO S.; AFONSO, CONRADO R. M.. Advanced characterization of bulk alloy and in-situ debris nanoparticles formed during wear of Fe-Nb-B ultrafine eutectic laser cladding coatings. JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T, v. 23, p. 15-pg., 2023-02-17. (13/05987-8, 17/27031-4)

FERREIRA, TALES; KOGA, GUILHERME YUUKI; GARGARELLA, PITER; KIMINAMI, CLAUDIO SHYINTI; BOTTA, WALTER JOSE; BOLFARINI, CLAUDEMIRO. New Al-alloys with dispersed stable quasicrystal approximant phases: Overcoming the barrier of conventional casting processing and microstructure design. JOURNAL OF MANUFACTURING PROCESSES, v. 98, p. 10-pg., 2023-05-11. (17/27031-4)

RODRIGUES, L. C. M.; KOGA, G. Y.; FREITAS, B. J. M.; FIGUEIRA, G.; GARGARELLA, P.; BOLFARINI, C.; KIMINAMI, C. S.; BOTTA, W. J.. Wear-resistant Fe68Cr8Mo4Nb4B16 glass former coatings-From powder production by gas atomization to coating build-up by Laser Powder Bed Fusion. SURFACE & COATINGS TECHNOLOGY, v. 441, p. 12-pg., 2022-07-15. (13/05987-8, 19/05885-7, 19/01829-5, 17/27031-4, 21/08514-0)

WANG, P.; QI, J. F.; CHEN, Z. W.; LAO, C. S.; HE, T. B.; LU, T. W.; GARGARELLA, P.; SCUDINO, S.. Microstructure and mechanical properties of novel high-entropy alloy particle reinforced aluminum matrix composites fabricated by selective laser melting. Journal of Alloys and Compounds, v. 868, JUL 5 2021. (17/27031-4)

MARTINS FREITAS, BRENDA JULIET; DE OLIVEIRA, VINICIUS ANTONIO; GARGARELLA, PITER; KOGA, GUILHERME YUUKI; BOLFARINI, CLAUDEMIRO. Microstructural characterization and wear resistance of boride-reinforced steel coatings produced by Selective Laser Melting (SLM). SURFACE & COATINGS TECHNOLOGY, v. 426, NOV 25 2021. (17/27031-4, 18/23810-1, 19/05885-7)

OLIVEIRA, ADRIEL P.; LIMA, LUIZ H. Q. R.; FELIPE, BIANCA C. A.; BOLFARINI, CLAUDEMIRO; COELHO, REGINALDO T.; GARGARELLA, PITER. Effect of microstructure and defect formation on the bending properties of additive manufactured H13 tool steel. JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T, v. 15, p. 3598-3609, NOV-DEC 2021. (18/15659-1, 16/11309-0, 17/27031-4)

BATALHA, RODOLFO LISBOA; PINOTTI, VITOR EDUARDO; ALNOAIMY, OMAR O. S.; BATALHA, WEVERSON CAPUTE; GUSTMANN, TOBIAS; KOSIBA, KONRAD; PAULY, SIMON; BOLFARINI, CLAUDEMIRO; KIMINAMI, CLAUDIO SHYINTI; GARGARELLA, PITER. icrostructure and properties of TiB2-reinforced Ti-35Nb-7Zr-5Ta processed by laser-powder bed fusio. Journal of Materials Research, NOV 2021. (13/05987-8, 17/27031-4)

DE ARAUJO, AYLANNA P. M.; PAULY, SIMON; BATALHA, RODOLFO L.; COURY, FRANCISCO G.; KIMINAMI, CLAUDIO S.; UHLENWINKEL, VOLKER; GARGARELLA, PITER. Additive manufacturing of a quasicrystal-forming Al95Fe2Cr2Ti1 alloy with remarkable high-temperature strength and ductility. ADDITIVE MANUFACTURING, v. 41, MAY 2021. (18/04209-5, 19/03010-3, 17/27031-4, 13/05987-8)

BATALHA, WEVERSON CAPUTE; BATALHA, RODOLFO LISBOA; KOSIBA, KONRAD; KIMINAMI, CLAUDIO SHYINTI; GARGARELLA, PITER. Effect of scanning strategy on microstructure and mechanical properties of a biocompatible Ti-35Nb-7Zr-5Ta alloy processed by laser-powder bed fusion. Journal of Materials Research, v. N/A, p. 11-pg., 2022-10-04. (17/27031-4, 13/05987-8)