A process optimization framework for laser direct energy deposition: Densification, microstructure, and mechanical properties of an Fe-Cr alloy

Whitt, Austin; Seede, Raiyan; Ye, Jiahui; Elverud, Michael; Vaughan, Matthew; Elwany, Alaa; Arroyave, Raymundo; Karaman, Ibrahim

doi:10.1016/j.jmapro.2022.11.028

A process optimization framework for laser direct energy deposition: Densification, microstructure, and mechanical properties of an Fe-Cr alloy

Journal Article · Mon Dec 05 00:00:00 EST 2022 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2022.11.028· OSTI ID:2421402

Whitt, Austin ^[1]; Seede, Raiyan ^[2]; Ye, Jiahui ^[2]; Elverud, Michael ^[2]; Vaughan, Matthew ^[2]; Elwany, Alaa ^[2]; Arroyave, Raymundo ^[2]; Karaman, Ibrahim ^[2]

Texas A & M Univ., College Station, TX (United States); OSTI
Texas A & M Univ., College Station, TX (United States)

Laser Direct Energy Deposition (DED) is a metal additive manufacturing technique with the ability to fabricate large and complex parts through deposition of metal powders. However, achieving high-density parts and targeted build heights using DED can be challenging due to the large number of highly sensitive process variables. This work proposes a robust fabrication parameter optimization framework to generate process maps for primary parameters in DED, including laser power, scan speed, mass flow rate, hatch spacing, and layer height. Simple single-track experiments were utilized to map out the parameter space, and a combination of geometric criteria for hatch spacing and layer height were proposed to determine parameter sets that achieve both targeted build heights and mitigate porosity formation. Using this framework, specimens with >99 % density and consistent mechanical properties were successfully fabricated over a wide range of process parameters for an Fe-9wt.%Cr (Fe9Cr) alloy, a surrogate for radiation damage-resistant reduced activation ferritic/martensitic (RAFM) steels. Processing these materials using DED is of particular interest in the development of plasma facing components for nuclear fusion applications. The microstructure and mechanical properties of as-printed Fe9Cr were characterized using optical and electron microscopy, X-ray diffraction, and uniaxial tensile tests. As-printed Fe9Cr displayed ~25 % elongation and ultimate tensile strengths of up to 475 MPa which is comparable to similar wrought alloys. Finally, the proposed framework will allow for accelerated DED parameter optimization for novel alloy systems, as well as open the possibility for local microstructure control while simultaneously mitigating defect formation.

View Accepted Manuscript (DOE)

Research Organization:: QuesTek Innovations, LLC, Evanston, IL (United States)

Sponsoring Organization:: USDOE; USDOE Office of Science (SC)

Grant/Contract Number:: SC0020032

OSTI ID:: 2421402

Alternate ID(s):: OSTI ID: 1905626

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Vol. 85; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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