In-situ synthesis of oxides by reactive process atmospheres during L-PBF of stainless steel

Haines, Michael P.; Peter, Nicolas J.; Babu, Sudarsanam S.; Jägle, Eric A.

doi:10.1016/j.addma.2020.101178

In-situ synthesis of oxides by reactive process atmospheres during L-PBF of stainless steel

Journal Article · Thu Mar 19 00:00:00 EDT 2020 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2020.101178· OSTI ID:1989584

Haines, Michael P. ^[1]; Peter, Nicolas J. ^[2]; Babu, Sudarsanam S. ^[3]; Jägle, Eric A. ^[2]

Univ. of Tennessee, Knoxville, TN (United States)
Max-Planck-Institut für Eisenforschung (Germany)
Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Traditionally, reactive gases such as oxygen (O₂) and carbon dioxide (CO₂) have been avoided during laser powder bed fusion (L-PBF) of metals and alloys based on the notion that it may lead to defect formation and poor properties. Here, in this work, we show that instead, these gases can be used to form sub-μm-sized oxide particles in-situ during the L-PBF process in an Fe-Cr-Al-Ti stainless steel and lead to improved room temperature and high-temperature mechanical properties. We manufactured cube samples using pure Ar and various reactive gas atmospheres, namely an O₂/Argon (Ar) mixture containing 0.2 % O₂ and CO₂/Ar mixtures containing up to 100 % CO₂. Co-axial measurements of infrared radiation emitted from the melt pool showed correlation to the presence of O₂ or CO₂ in the gas mixture. Builds produced under CO₂-containing atmosphere contained complex oxides with an average diameter of ~40 nm, an Al-rich core and a Ti-rich shell. Due to the high cooling rates typical to L-PBF, agglomeration of oxides and slag formation on the surface of the samples could almost be entirely avoided. Compression tests at temperatures up to 800 °C showed that the samples produced in 100 % CO₂ have about 20 % higher yield stress compared to samples produced in Ar. The paper concludes with a discussion of the formation mechanism of the observed oxides. Our results show that in-situ reactions during additive manufacturing processes are a promising pathway to the synthesis of particle-reinforced alloys.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); US Department of the Navy, Office of Naval Research (ONR)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1989584

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 33; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (45)

Fabrication of Fe-Cr-Al Oxide Dispersion Strengthened PM2000 Alloy Using Selective Laser Melting Walker, John C.; Berggreen, Kaj M.; Jones, Andy R. Advanced Engineering Materials, Vol. 11, Issue 7 https://doi.org/10.1002/adem.200800407	journal	July 2009
Laser welding of oxide dispersion-strengthened alloy MA754 Molian, P. A.; Yang, Y. M.; Patnaik, P. C. Journal of Materials Science, Vol. 27, Issue 10 https://doi.org/10.1007/BF00540691	journal	January 1992
A general model for partitioning of gases between a metal and its plasma environment Mundra, K.; Debroy, T. Metallurgical and Materials Transactions B, Vol. 26, Issue 1 https://doi.org/10.1007/BF02648987	journal	February 1995
Mechanisms of inclusion formation in Al−Ti−Si−Mn deoxidized steel weld metals Kluken, A. O.; Grong, Ø. Metallurgical Transactions A, Vol. 20, Issue 8 https://doi.org/10.1007/BF02665492	journal	August 1989
A model for the silicon-manganese deoxidation of steel weld metals Grong, O.; Siewert, T. A.; Martins, G. P. Metallurgical Transactions A, Vol. 17, Issue 10 https://doi.org/10.1007/BF02817277	journal	October 1986
A Study on the Laser Spatter and the Oxidation Reactions During Selective Laser Melting of 316L Stainless Steel, Al-Si10-Mg, and Ti-6Al-4V Simonelli, Marco; Tuck, Chris; Aboulkhair, Nesma T. Metallurgical and Materials Transactions A, Vol. 46, Issue 9 https://doi.org/10.1007/s11661-015-2882-8	journal	April 2015
Alternative Fabrication Routes toward Oxide-Dispersion-Strengthened Steels and Model Alloys Bergner, Frank; Hilger, Isabell; Virta, Jouko Metallurgical and Materials Transactions A, Vol. 47, Issue 11 https://doi.org/10.1007/s11661-016-3616-2	journal	July 2016
Localized Changes of Stainless Steel Powder Characteristics During Selective Laser Melting Additive Manufacturing Galicki, D.; List, F.; Babu, S. S. Metallurgical and Materials Transactions A, Vol. 50, Issue 3 https://doi.org/10.1007/s11661-018-5072-7	journal	January 2019
Additive Manufacturing of 17-4 PH Stainless Steel: Post-processing Heat Treatment to Achieve Uniform Reproducible Microstructure Cheruvathur, Sudha; Lass, Eric A.; Campbell, Carelyn E. JOM, Vol. 68, Issue 3 https://doi.org/10.1007/s11837-015-1754-4	journal	December 2015
Rapid Solidification: Selective Laser Melting of AlSi10Mg Tang, Ming; Pistorius, P. Chris; Narra, Sneha JOM, Vol. 68, Issue 3 https://doi.org/10.1007/s11837-015-1763-3	journal	January 2016
Thermal conductivity of packed beds: A review Tsotsas, E.; Martin, H. Chemical Engineering and Processing: Process Intensification, Vol. 22, Issue 1 https://doi.org/10.1016/0255-2701(87)80025-9	journal	July 1987
Influence of the alloy grain size on the oxidation behaviour of PM2000 alloy Pérez, P. Corrosion Science, Vol. 44, Issue 8 https://doi.org/10.1016/S0010-938X(01)00182-2	journal	August 2002
Effect of microalloying on precipitate evolution in ferritic welds and implications for toughness Narayanan, Badri K.; Kovarik, L.; Sarosi, Peter M. Acta Materialia, Vol. 58, Issue 3 https://doi.org/10.1016/j.actamat.2009.09.056	journal	February 2010
The effect of oxygen on transitional Marangoni flow in laser spot welding Zhao, C. X.; Kwakernaak, C.; Pan, Y. Acta Materialia, Vol. 58, Issue 19 https://doi.org/10.1016/j.actamat.2010.07.056	journal	November 2010
Mechanical response and deformation mechanisms of ferritic oxide dispersion strengthened steel structures produced by selective laser melting Boegelein, Thomas; Dryepondt, Sebastien N.; Pandey, Amit Acta Materialia, Vol. 87 https://doi.org/10.1016/j.actamat.2014.12.047	journal	April 2015
Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones Khairallah, Saad A.; Anderson, Andrew T.; Rubenchik, Alexander Acta Materialia, Vol. 108 https://doi.org/10.1016/j.actamat.2016.02.014	journal	April 2016
Microstructure and mechanical properties investigation of CP titanium processed by selective laser melting (SLM) Wysocki, Bartłomiej; Maj, Piotr; Krawczyńska, Agnieszka Journal of Materials Processing Technology, Vol. 241 https://doi.org/10.1016/j.jmatprotec.2016.10.022	journal	March 2017
The influence of Helium bubbles on the critical resolved shear stress of dispersion strengthened alloys Bakó, B.; Samaras, M.; Weygand, D. Journal of Nuclear Materials, Vol. 386-388 https://doi.org/10.1016/j.jnucmat.2008.12.074	journal	April 2009
Oxide inclusions in laser additive manufactured stainless steel and their effects on impact toughness and stress corrosion cracking behavior Lou, Xiaoyuan; Andresen, Peter L.; Rebak, Raul B. Journal of Nuclear Materials, Vol. 499 https://doi.org/10.1016/j.jnucmat.2017.11.036	journal	February 2018
Characterisation of a complex thin walled structure fabricated by selective laser melting using a ferritic oxide dispersion strengthened steel Boegelein, Thomas; Louvis, Eleftherios; Dawson, Karl Materials Characterization, Vol. 112 https://doi.org/10.1016/j.matchar.2015.11.021	journal	February 2016
Investigation into spatter behavior during selective laser melting of AISI 316L stainless steel powder Liu, Yang; Yang, Yongqiang; Mai, Shuzhen Materials & Design, Vol. 87 https://doi.org/10.1016/j.matdes.2015.08.086	journal	December 2015
Efficient additive manufacturing production of oxide- and nitride-dispersion-strengthened materials through atmospheric reactions in liquid metal deposition Springer, H.; Baron, C.; Szczepaniak, A. Materials & Design, Vol. 111 https://doi.org/10.1016/j.matdes.2016.08.084	journal	December 2016
Mechanisms and characteristics of spatter generation in SLM processing and its effect on the properties Wang, Di; Wu, Shibiao; Fu, Fan Materials & Design, Vol. 117 https://doi.org/10.1016/j.matdes.2016.12.060	journal	March 2017
Oxide dispersion-strengthened alloys generated by laser metal deposition of laser-generated nanoparticle-metal powder composites Doñate-Buendía, Carlos; Frömel, Felix; Wilms, Markus B. Materials & Design, Vol. 154 https://doi.org/10.1016/j.matdes.2018.05.044	journal	September 2018
Marangoni convection and weld shape variations in Ar–O2 and Ar–CO2 shielded GTA welding Lu, Shanping; Fujii, Hidetoshi; Nogi, Kiyoshi Materials Science and Engineering: A, Vol. 380, Issue 1-2 https://doi.org/10.1016/j.msea.2004.05.057	journal	August 2004
Hardened austenite steel with columnar sub-grain structure formed by laser melting Saeidi, K.; Gao, X.; Zhong, Y. Materials Science and Engineering: A, Vol. 625 https://doi.org/10.1016/j.msea.2014.12.018	journal	February 2015
Impact of composition on the heat treatment response of additively manufactured 17–4 PH grade stainless steel Meredith, S. D.; Zuback, J. S.; Keist, J. S. Materials Science and Engineering: A, Vol. 738 https://doi.org/10.1016/j.msea.2018.09.066	journal	December 2018
Characterization of nano-scale oxides in austenitic stainless steel processed by powder bed fusion Yan, Fuyao; Xiong, Wei; Faierson, Eric Scripta Materialia, Vol. 155 https://doi.org/10.1016/j.scriptamat.2018.06.011	journal	October 2018
Reactive gas shielding during laser surface alloying for production of hard coatings Babu, S. S.; Kelly, S. M.; Murugananth, M. Surface and Coatings Technology, Vol. 200, Issue 8 https://doi.org/10.1016/j.surfcoat.2005.02.160	journal	January 2006
Optical emission spectroscopy of metal vapor dominated laser-arc hybrid welding plasma Ribic, B.; Burgardt, P.; DebRoy, T. Journal of Applied Physics, Vol. 109, Issue 8 https://doi.org/10.1063/1.3552307	journal	April 2011
Spectroscopic measurements of laser induced plasma during welding with CO ₂ laser Szymański, Z.; Kurzyna, J. Journal of Applied Physics, Vol. 76, Issue 12 https://doi.org/10.1063/1.357952	journal	December 1994
Review of selective laser melting: Materials and applications Yap, C. Y.; Chua, C. K.; Dong, Z. L. Applied Physics Reviews, Vol. 2, Issue 4 https://doi.org/10.1063/1.4935926	journal	December 2015
Characterization of laser-induced plasmas as a complement to high-explosive large-scale detonations Kimblin, Clare; Trainham, Rusty; Capelle, Gene A. AIP Advances, Vol. 7, Issue 9 https://doi.org/10.1063/1.4999793	journal	September 2017
The metallurgy and processing science of metal additive manufacturing Sames, W. J.; List, F. A.; Pannala, S. International Materials Reviews, Vol. 61, Issue 5 https://doi.org/10.1080/09506608.2015.1116649	journal	March 2016
Experimental study of the dynamical coupling between the induced vapour plume and the melt pool for Nd–Yag CW laser welding Fabbro, Rémy; Slimani, Sonia; Doudet, Ivan Journal of Physics D: Applied Physics, Vol. 39, Issue 2 https://doi.org/10.1088/0022-3727/39/2/023	journal	January 2006
Model for inclusion formation in low alloy steel welds Babu, S. S.; David, S. A.; Vitek, J. M. Science and Technology of Welding and Joining, Vol. 4, Issue 5 https://doi.org/10.1179/136217199101537879	journal	October 1999
Laser additive manufacturing of metallic components: materials, processes and mechanisms Gu, D. D.; Meiners, W.; Wissenbach, K. International Materials Reviews, Vol. 57, Issue 3, p. 133-164 https://doi.org/10.1179/1743280411Y.0000000014	journal	May 2012
Friction stir welding of PM2000 ODS alloy Dawson, K.; Cater, S.; Tatlock, G. J. Materials Science and Technology, Vol. 30, Issue 13 https://doi.org/10.1179/1743284714Y.0000000553	journal	April 2014
Development of macro- and microstructures of carbon–manganese low alloy steel welds: inclusion formation Babu, S. S.; David, S. A.; Vitek, J. M. Materials Science and Technology, Vol. 11, Issue 2 https://doi.org/10.1179/mst.1995.11.2.186	journal	February 1995
Coarsening of oxide inclusions in low alloy steel welds Babu, S. S.; David, S. A.; DebRoy, T. Science and Technology of Welding and Joining, Vol. 1, Issue 1 https://doi.org/10.1179/stw.1996.1.1.17	journal	February 1996
Enhanced dissolution of nitrogen during gas tungsten arc welding of steels Palmer, T. A.; DebRoy, T. Science and Technology of Welding and Joining, Vol. 3, Issue 4 https://doi.org/10.1179/stw.1998.3.4.190	journal	August 1998
In-Flight Oxidation of Stainless Steel Particles in Plasma Spraying Syed, A. A.; Denoirjean, A.; Denoirjean, P. Journal of Thermal Spray Technology, Vol. 14, Issue 1 https://doi.org/10.1361/10599630522675	journal	March 2005
CO ₂ shielding gas effects in laser welding mild steel Abbott, D. H.; Albright, C. E. Journal of Laser Applications, Vol. 6, Issue 2 https://doi.org/10.2351/1.4745339	journal	June 1994
Inclusion Formation and Microstructure Evolution in Low Alloy Steel Welds. Babu, S. S.; David, S. A. ISIJ International, Vol. 42, Issue 12 https://doi.org/10.2355/isijinternational.42.1344	journal	January 2002
Spectra of optical radiation from welding arcs. Okuno, Tsutomu INDUSTRIAL HEALTH, Vol. 23, Issue 1 https://doi.org/10.2486/indhealth.23.53	journal	January 1985

Similar Records

Scale formation mechanisms of martensitic steels in high CO{sub 2}/H{sub 2}O-containing gases simulating oxyfuel environments

Journal Article · Wed Jul 01 00:00:00 EDT 2009 · Materials at High Temperatures · OSTI ID:21197972

Studies concerning the effect of nitrogen on the oxidation behavior of TiAl-based intermetallics at 900{degrees}C

Journal Article · Thu Nov 30 23:00:00 EST 1995 · Oxidation of Metals · OSTI ID:241151

The oxidation behavior of Fe-20Cr alloy foils in a synthetic exhaust-gas atmosphere

Journal Article · Sat Nov 30 23:00:00 EST 1996 · Oxidation of Metals · OSTI ID:482497

Related Subjects

36 MATERIALS SCIENCE
L-PBFODS alloys
additive manufacturing
reactive process atmospheres
stainless steel

In-situ synthesis of oxides by reactive process atmospheres during L-PBF of stainless steel

Citation Formats

References (45)

Similar Records

Related Subjects