On the melt pool dynamic of voxel-controlled metal matrix composites via hybrid additive manufacturing: Laser powder bed fusion and ink-jetting

Ghayoor, Milad; Sadeghi, Omid; Cox, Bryce; Gess, Joshua; Pasebani, Somayeh

doi:10.1016/j.jmapro.2023.01.059

On the melt pool dynamic of voxel-controlled metal matrix composites via hybrid additive manufacturing: Laser powder bed fusion and ink-jetting

Journal Article · Fri Feb 03 00:00:00 EST 2023 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2023.01.059· OSTI ID:2418560

Ghayoor, Milad ^[1]; Sadeghi, Omid ^[2]; Cox, Bryce ^[3]; Gess, Joshua ^[3]; Pasebani, Somayeh ^[4]

Oregon State Univ., Corvallis, OR (United States); Advanced Technology and Manufacturing Institute (ATAMI), Corvallis, OR (United States); OSTI
Phosio Corporation, Corvallis, OR (United States)
Oregon State Univ., Corvallis, OR (United States)
Oregon State Univ., Corvallis, OR (United States); Advanced Technology and Manufacturing Institute (ATAMI), Corvallis, OR (United States)

In this study, the effect of the addition of reinforcement nanoparticles to the 316L matrix by adopting ex-situ and in-situ method (drop on demand jetting) to produce 316L/Al₂O₃ nanocomposite was investigated. In the ex-situ method, the Al₂O₃ nanoparticles (NPs) were lightly mixed with 316L powder and processed by laser powder bed fusion. In the in-situ method, an ethanol-based ink containing Al₁₃ nanoclusters (NCs) was added to 316L powder and then processed by laser. Both ex-situ and in-situ method produced nanocomposites with Al-Si-Mn-O-enriched precipitations within the 316L matrix. The addition of NPs/NCs to the 316L matrix, altered the geometrical characteristic of the single-track melt pools. At the same laser power, with increasing the amount of Al₂O₃ NPs and Al₁₃ NCs the melt pool deepened due to reduced thermal conductivity and prolonged liquid presence. Further, as a result, 316L/1 wt% Al₁₃ NCs deposited single track showed larger grains in comparison to 316L single track. At a high laser power of 150W, the Marangoni flow and the buoyancy force caused the nanoparticles to agglomerate and float to the top surface of tracks; therefore, the wt% fraction of precipitation was drastically reduced due to the loss of Al. The 316L/Al₂O₃ NPs and 316L/Al₁₃ NCs exhibited the microhardness of 285 ± 13 HV and 293 ± 7 HV, respectively, higher than the deposited 316L single track, 265 ± 15 HV. Lastly, a hybrid LPBF+ink-jet printer was adopted to selectively change the composition of different zones by adding Al₁₃ NCs ink to 316L and producing a voxel-controlled metal matrix composite.

View Accepted Manuscript (DOE)

Research Organization:: American Institute of Chemical Engineers (AIChE), New York, NY (United States)

Sponsoring Organization:: National Science Foundation (NSF); USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0007888

OSTI ID:: 2418560

Alternate ID(s):: OSTI ID: 1926751

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Journal Issue: C Vol. 89; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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316L
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY
Hybrid additive manufacturing
Ink-jetting
Laser powder bed fusion
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Nanocluster

On the melt pool dynamic of voxel-controlled metal matrix composites via hybrid additive manufacturing: Laser powder bed fusion and ink-jetting

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