An additive manufacturing design approach to achieving high strength and ductility in traditionally brittle alloys via laser powder bed fusion

Babuska, Tomas Farley; Johnson, Kyle; Verdonik, Trevor; Subia, Samuel Ramirez; Krick, Brandon; Susan, Donald F.; Kustas, Andrew

doi:10.1016/j.addma.2020.101187

An additive manufacturing design approach to achieving high strength and ductility in traditionally brittle alloys via laser powder bed fusion

Journal Article · Wed Apr 22 00:00:00 EDT 2020 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2020.101187· OSTI ID:1618101

Babuska, Tomas Farley ^[1]; Johnson, Kyle ^[2]; Verdonik, Trevor ^[3]; Subia, Samuel Ramirez ^[2]; Krick, Brandon ^[3]; Susan, Donald F. ^[2]; Kustas, Andrew ^[2]

Sandia National Lab. (SNL-NM), Albuquerque, NM (United States); Lehigh Univ., Bethlehem, PA (United States)
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Lehigh Univ., Bethlehem, PA (United States)

Additive Manufacturing (AM) presents unprecedented opportunities to enable design freedom in parts that are unachievable via conventional manufacturing. However, AM-processed components generally lack the necessary performance metrics for widespread commercial adoption. We present a novel AM processing and design approach using removable heat sink artifacts to tailor the mechanical properties of traditionally low strength and low ductility alloys. The design approach is demonstrated with the Fe-50 at.% Co alloy, as a model material of interest for electromagnetic applications. AM-processed components exhibited unprecedented performance, with a 300 % increase in strength and an order-of-magnitude improvement in ductility relative to conventional wrought material. These results are discussed in the context of product performance, production yield, and manufacturing implications toward enabling the design and processing of high-performance, next-generation components, and alloys.

View Accepted Manuscript (DOE)

Research Organization:: Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC04-94AL85000

OSTI ID:: 1618101

Alternate ID(s):: OSTI ID: 2325531

Report Number(s):: SAND--2020-4661J; 685855

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: C Vol. 34; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
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An additive manufacturing design approach to achieving high strength and ductility in traditionally brittle alloys via laser powder bed fusion

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