Here, the additive manufacture of compositionally graded Al/Cu parts by laser engineered net shaping (LENS) is demonstrated. The use of a blue light build laser enabled deposition on a Cu substrate. The thermal gradient and rapid solidification inherent to selective laser melting enabled mass transport of Cu up to 4 mm from a Cu substrate through a pure Al deposition, providing a means of producing gradients with finer step sizes than the printed layer thicknesses. Divorcing gradient continuity from layer or particle size makes LENS a potentially enabling technology for the manufacture of graded density impactors for ramp compression experiments. Printing graded structures with pure Al, however, was prevented by the growth of Al2Cu3 dendrites and acicular grains amid a matrix of Al2Cu. A combination of adding TiB2 grain refining powder and actively varying print layer composition suppressed the dendritic growth mode and produced an equiaxed microstructure in a compositionally graded part. Material phase was characterized for crystal structure and nanoindentation hardness to enable a discussion of phase evolution in the rapidly solidifying melt pool of a LENS print.
Abere, Michael J., et al. "Refining Microstructures in Additively Manufactured Al/Cu Gradients Through TiB<sub>2</sub> Inclusions." JOM. Journal of the Minerals, Metals & Materials Society, vol. 76, May. 2024. https://doi.org/10.1007/s11837-024-06654-8
Abere, Michael J., Choi, Hyein, Van Bastian, Levi, Jauregui, Luis, Babuska, Tomas F., Rodriguez, Mark A., DelRio, Frank W., Whetten, Shaun R., & Kustas, Andrew B. (2024). Refining Microstructures in Additively Manufactured Al/Cu Gradients Through TiB<sub>2</sub> Inclusions. JOM. Journal of the Minerals, Metals & Materials Society, 76. https://doi.org/10.1007/s11837-024-06654-8
Abere, Michael J., Choi, Hyein, Van Bastian, Levi, et al., "Refining Microstructures in Additively Manufactured Al/Cu Gradients Through TiB<sub>2</sub> Inclusions," JOM. Journal of the Minerals, Metals & Materials Society 76 (2024), https://doi.org/10.1007/s11837-024-06654-8
@article{osti_2394706,
author = {Abere, Michael J. and Choi, Hyein and Van Bastian, Levi and Jauregui, Luis and Babuska, Tomas F. and Rodriguez, Mark A. and DelRio, Frank W. and Whetten, Shaun R. and Kustas, Andrew B.},
title = {Refining Microstructures in Additively Manufactured Al/Cu Gradients Through TiB<sub>2</sub> Inclusions},
annote = {Here, the additive manufacture of compositionally graded Al/Cu parts by laser engineered net shaping (LENS) is demonstrated. The use of a blue light build laser enabled deposition on a Cu substrate. The thermal gradient and rapid solidification inherent to selective laser melting enabled mass transport of Cu up to 4 mm from a Cu substrate through a pure Al deposition, providing a means of producing gradients with finer step sizes than the printed layer thicknesses. Divorcing gradient continuity from layer or particle size makes LENS a potentially enabling technology for the manufacture of graded density impactors for ramp compression experiments. Printing graded structures with pure Al, however, was prevented by the growth of Al2Cu3 dendrites and acicular grains amid a matrix of Al2Cu. A combination of adding TiB2 grain refining powder and actively varying print layer composition suppressed the dendritic growth mode and produced an equiaxed microstructure in a compositionally graded part. Material phase was characterized for crystal structure and nanoindentation hardness to enable a discussion of phase evolution in the rapidly solidifying melt pool of a LENS print.},
doi = {10.1007/s11837-024-06654-8},
url = {https://www.osti.gov/biblio/2394706},
journal = {JOM. Journal of the Minerals, Metals & Materials Society},
issn = {ISSN 1047-4838},
volume = {76},
place = {United States},
publisher = {Springer},
year = {2024},
month = {05}}
Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)
Sponsoring Organization:
USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE National Nuclear Security Administration (NNSA)
Grant/Contract Number:
NA0003525
OSTI ID:
2394706
Report Number(s):
SAND--2024-08350J
Journal Information:
JOM. Journal of the Minerals, Metals & Materials Society, Journal Name: JOM. Journal of the Minerals, Metals & Materials Society Vol. 76; ISSN 1047-4838
Park, Hye-Sook; Barton, Nathan; Belof, Jonathan L.
SHOCK COMPRESSION OF CONDENSED MATTER - 2011: Proceedings of the Conference of the American Physical Society Topical Group on Shock Compression of Condensed Matter, AIP Conference Proceedingshttps://doi.org/10.1063/1.3686536
Philosophical Transactions of the Royal Society of London. Series A: Mathematical, Physical and Engineering Sciences, Vol. 361, Issue 1804https://doi.org/10.1098/rsta.2002.1147
