Directed energy deposition additive manufacturing of functionally graded Al-W composites

Kelly, J. P.; Elmer, J. W.; Ryerson, F. J.; Lee, J. R.I.; Haslam, J. J.

doi:10.1016/j.addma.2021.101845

Title: Directed energy deposition additive manufacturing of functionally graded Al-W composites

Journal Article · Fri Jan 22 00:00:00 EST 2021 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2021.101845· OSTI ID:1818415

Kelly, J. P. ^[1]; Elmer, J. W. ^[1]; Ryerson, F. J. ^[1]; Lee, J. R.I. ^[1]; Haslam, J. J. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Directed energy deposition using laser heat sources (DED-L) is a metal additive manufacturing method that can be used to fabricate functionally graded materials by feeding multiple powder streams directly into a laser-generated melt pool. Additionally, the composition can be spatially varied by independent control of the materials feed rates. DED-L additive manufacturing is used in this work to create continuously graded Al/W composites that span 0–55 vol% W in Al over length scales from 0.6 to 1.2 mm with individual layers on the order of 0.1 mm and powder particle sizes on the order of 10 µm. The obtained composition and thickness ranges are comparable to those typically achieved using conventional powder metallurgy approaches and enables fabrication of composites to be used as a high impedance graded density impactor (GDI) in dynamic ramp compression experiments to study matter under extreme conditions. DED-L additive manufacturing of a GDI presents an opportunity to reduce GDI fabrication time to less than a day compared to many weeks by conventional methods. It is also possible to scale the deposition by DED-L to essentially unlimited dimensions in the lateral directions, whereas conventional methods become limited.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1818415

Alternate ID(s):: OSTI ID: 2202883

Report Number(s):: LLNL-JRNL-813734; 1020537

Journal Information:: Additive Manufacturing, Vol. 39, Issue na; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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42 ENGINEERING
36 MATERIALS SCIENCE
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Functionally graded materials
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Title: Directed energy deposition additive manufacturing of functionally graded Al-W composites

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