Development of volume deposition on cast iron by additive manufacturing
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)
ORNL partnered with Cummins to demonstrate the feasibility of using additive manufacturing techniques to help develop repair techniques for refurbished cast iron engine blocks. Cummins is interested in the refurbished engine business due to the increased cost savings and reduced emissions. It is expected that by refurbishing engines could help reduce the green house gas emissions by as much as 85%. Though such repair techniques are possible in principle there has been no major industry in the automotive sector that has deployed this technology. Therefore phase-1 would seek to evaluate the feasibility of using the laser directed energy deposition technique to repair cast iron engine blocks. The objective of the phase-1 would be to explore various strategies and understand the challenges involved. During phase-1 deposits were made using Inconel-718, Nickel, Nr-Cr-B braze filler. Inconel 718 builds showed significant cracking in the heat-affected zone in the cast iron. Nickel was used to reduce the cracking in the cast iron substrate, however the Ni builds did not wet the substrate sufficiently resulting in poor dimensional tolerance. In order to increase wetting the Ni was alloyed with the Ni-Cr-B braze to decrease the surface tension of Ni. This however resulted in significant cracks in the build due to shrinkage stresses associated with multiple thermal cycling. Hence to reduce the residual stresses in the builds the DMD-103D equipment was modified and the cast iron block was pre heated using cartridge heaters. Inconel-718 alloyed with Ni was deposited on the engine block. The pre-heated deposits showed a reduced susceptibility to cracking. If awarded the phase-2 of the project would aim to develop process parameters to achieve a crack free deposit engine block.
- Research Organization:
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- DOE Contract Number:
- AC05-00OR22725
- OSTI ID:
- 1343534
- Report Number(s):
- ORNL/TM-2016/713; ED2802000; CEED492; CRADA/NFE-16-06108
- Country of Publication:
- United States
- Language:
- English
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