Strength-ductility synergy through microstructural and compositional heterogeneity in directed energy deposition additive manufacturing of face-centered cubic materials

Ahsan, Md R.U.; Hmeidat, Nadim S.; Islam, Saiful; Fan, Xuesong; Poplawsky, Jonathan D.; Liaw, Peter K.; Lee, Yousub; Compton, Brett G.; Jeon, Yongho; Kim, Duck Bong

doi:10.1016/j.jmrt.2024.10.253

Strength-ductility synergy through microstructural and compositional heterogeneity in directed energy deposition additive manufacturing of face-centered cubic materials

Journal Article · Fri Nov 01 04:00:00 EDT 2024 · Journal of Materials Research and Technology

DOI:https://doi.org/10.1016/j.jmrt.2024.10.253· OSTI ID:2477523

Ahsan, Md R.U. ^[1]; ^[2]; ^[1]; Fan, Xuesong ^[3]; ^[4]; Liaw, Peter K. ^[3]; ^[2]; Compton, Brett G. ^[3]; Jeon, Yongho ^[5]; ^[1]

Tennessee Technological Univ., Cookeville, TN (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Univ. of Tennessee, Knoxville, TN (United States)
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Center for Nanophase Materials Sciences (CNMS)
Ajou University, Suwon (Korea, Republic of)

Directed energy deposition (DED) is an additive manufacturing (AM) process based on welding technology and offers the advantages of large build volume, high deposition rate, and ability to fabricate multi-material parts. Epitaxial continuous columnar grain growth is a characteristic microstructural feature of DED processed alloys. In this study, a bamboo-like microstructure (periodic alternation of equiaxed and columnar structure) was produced by adopting an intermittent deposition strategy in 316L stainless steel and Inconel 625. The formation of a bamboo-like alternating microstructure was confirmed through electron backscattered diffraction (EBSD) analysis. Hardness mapping showed that the columnar to equiaxed transition (CET) occurred at the region right below the fusion line. A finite element (FE) model was used to investigate the relationship between the temperature gradient (G) and the solidification rate (R). The FE model showed a low G/R ratio at the region right below the interface promoting the CET. The grain size and material-dependent deformation behaviors are analyzed using digital image correlation (DIC). The lower deformation on the fine-grain regions observed in DIC analysis is attributed to a higher strain hardening rate, which is confirmed through dislocation density analysis on a tensile-interrupted specimen. The periodically alternating grain size coupled with the microstructural changes caused by intermittent deposition strategy result in a better strength-ductility synergy in both single-material and bimetallic specimens.

View Accepted Manuscript (DOE)

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

Sponsoring Organization:: National Science Foundation (NSF); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); National Research Foundation of Korea (NRF)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2477523

Journal Information:: Journal of Materials Research and Technology, Journal Name: Journal of Materials Research and Technology Vol. 33; ISSN 2238-7854

Publisher:: Brazilian Metallurgical, Materials and Mining AssociationCopyright Statement

Country of Publication:: United States

Language:: English

References (47)

Mapping and Assessing Plastic Deformation Using EBSD Brewer, Luke N.; Field, David P.; Merriman, Colin C. Electron Backscatter Diffraction in Materials Science https://doi.org/10.1007/978-0-387-88136-2_18	book	January 2009
On the strain-hardening parameters of metals Kleemola, H. J.; Nieminen, M. A. Metallurgical Transactions, Vol. 5, Issue 8 https://doi.org/10.1007/BF02644152	journal	August 1974
Morphology investigation on direct current pulsed gas tungsten arc welded additive layer manufactured Ti6Al4V alloy Wang, Fude; Williams, Stewart; Rush, Matthew The International Journal of Advanced Manufacturing Technology, Vol. 57, Issue 5-8 https://doi.org/10.1007/s00170-011-3299-1	journal	April 2011
Heat treatment effects on Inconel 625 components fabricated by wire + arc additive manufacturing (WAAM)—part 1: microstructural characterization Tanvir, A. N. M.; Ahsan, Md. R. U.; Ji, Changwook The International Journal of Advanced Manufacturing Technology, Vol. 103, Issue 9-12 https://doi.org/10.1007/s00170-019-03828-6	journal	May 2019
Wire arc additive manufacturing of high-strength low alloy steels: study of process parameters and their influence on the bead geometry and mechanical characteristics Yildiz, Ahmet Suat; Davut, Kemal; Koc, Barış The International Journal of Advanced Manufacturing Technology, Vol. 108, Issue 11-12 https://doi.org/10.1007/s00170-020-05482-9	journal	June 2020
Heat treatment effects on Inconel 625 components fabricated by wire + arc additively manufacturing (WAAM)—part 2: mechanical properties Tanvir, A. N. M.; Ahsan, Md R. U.; Seo, Gijeong The International Journal of Advanced Manufacturing Technology, Vol. 110, Issue 7-8 https://doi.org/10.1007/s00170-020-05980-w	journal	August 2020
Microstructural evolutions in dissimilar welds between AISI 310 austenitic stainless steel and Inconel 657 Naffakh, H.; Shamanian, M.; Ashrafizadeh, F. Journal of Materials Science, Vol. 45, Issue 10 https://doi.org/10.1007/s10853-010-4227-8	journal	January 2010
Microstructural Evolution with a Wide Range of Solidification Cooling Rates in a Ni-Based Superalloy Zhang, Yongjun; Huang, Bin; Li, Jianguo Metallurgical and Materials Transactions A, Vol. 44, Issue 4 https://doi.org/10.1007/s11661-013-1645-7	journal	February 2013
Dislocation densities and strain hardening rate in some intermetallic compounds Viguier, B. Materials Science and Engineering: A, Vol. 349, Issue 1-2 https://doi.org/10.1016/S0921-5093(02)00785-2	journal	May 2003
Geometrically necessary dislocation and size-dependent plasticity Gao, Huajian; Huang, Yonggang Scripta Materialia, Vol. 48, Issue 2 https://doi.org/10.1016/S1359-6462(02)00329-9	journal	January 2003
Geometrically necessary dislocations and strain-gradient plasticity: a few critical issues Kubin, L. P.; Mortensen, A. Scripta Materialia, Vol. 48, Issue 2 https://doi.org/10.1016/S1359-6462(02)00335-4	journal	January 2003
Functionally graded material of 304L stainless steel and inconel 625 fabricated by directed energy deposition: Characterization and thermodynamic modeling Carroll, Beth E.; Otis, Richard A.; Borgonia, John Paul Acta Materialia, Vol. 108 https://doi.org/10.1016/j.actamat.2016.02.019	journal	April 2016
Additive manufacturing of a functionally graded material from Ti-6Al-4V to Invar: Experimental characterization and thermodynamic calculations Bobbio, Lourdes D.; Otis, Richard A.; Borgonia, John Paul Acta Materialia, Vol. 127 https://doi.org/10.1016/j.actamat.2016.12.070	journal	April 2017
Three-dimensional modeling of grain structure evolution during welding of an aluminum alloy Wei, H. L.; Elmer, J. W.; DebRoy, T. Acta Materialia, Vol. 126 https://doi.org/10.1016/j.actamat.2016.12.073	journal	March 2017
Towards understanding grain nucleation under Additive Manufacturing solidification conditions Prasad, Arvind; Yuan, Lang; Lee, Peter Acta Materialia, Vol. 195 https://doi.org/10.1016/j.actamat.2020.05.012	journal	August 2020
Effect of build direction on the microstructure evolution and their mechanical properties using GTAW based wire arc additive manufacturing Tripathi, Umashankar; Saini, Nitin; Mulik, Rahul S. CIRP Journal of Manufacturing Science and Technology, Vol. 37 https://doi.org/10.1016/j.cirpj.2022.01.010	journal	May 2022
Monte Carlo simulation of grain growth in heat-affected zone of 12wt.% Cr ferritic stainless steel hybrid welds Zhang, Z. Z.; Wu, C. S. Computational Materials Science, Vol. 65 https://doi.org/10.1016/j.commatsci.2012.07.040	journal	December 2012
A sensitivity analysis of the columnar-to-equiaxed transition for Ni-based superalloys in electron beam additive manufacturing Haines, M.; Plotkowski, A.; Frederick, C. L. Computational Materials Science, Vol. 155 https://doi.org/10.1016/j.commatsci.2018.08.064	journal	December 2018
Achieving material diversity in wire arc additive manufacturing: Leaping from alloys to composites via wire innovation Yi, Hao; Jia, Le; Ding, Jialuo International Journal of Machine Tools and Manufacture, Vol. 194 https://doi.org/10.1016/j.ijmachtools.2023.104103	journal	January 2024
Modeling and simulation of the columnar-to-equiaxed transition during laser melting deposition of Invar alloy Zhan, Xiaohong; Lin, Xin; Gao, Zhuanni Journal of Alloys and Compounds, Vol. 755 https://doi.org/10.1016/j.jallcom.2018.04.313	journal	July 2018
A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement Wu, Bintao; Pan, Zengxi; Ding, Donghong Journal of Manufacturing Processes, Vol. 35 https://doi.org/10.1016/j.jmapro.2018.08.001	journal	October 2018
Current mode effects on weld bead geometry and heat affected zone in pulsed wire arc additive manufacturing of Ti-6-4 and Inconel 718 Benakis, Michalis; Costanzo, Davide; Patran, Alin Journal of Manufacturing Processes, Vol. 60 https://doi.org/10.1016/j.jmapro.2020.10.018	journal	December 2020
Phase stability and mechanical properties of wire + arc additively manufactured H13 tool steel at elevated temperatures Tanvir, A. N. M.; Ahsan, Md. R. U.; Seo, Gijeong Journal of Materials Science & Technology, Vol. 67 https://doi.org/10.1016/j.jmst.2020.04.085	journal	March 2021
Microstructures and mechanical behavior of the bimetallic additively-manufactured structure (BAMS) of austenitic stainless steel and Inconel 625 Ahsan, Md. R. U.; Fan, Xuesong; Seo, Gi-Jeong Journal of Materials Science & Technology, Vol. 74 https://doi.org/10.1016/j.jmst.2020.10.001	journal	May 2021
Wire arc additive manufacturing of metals: A review on processes, materials and their behaviour Srivastava, Manu; Rathee, Sandeep; Tiwari, Ankit Materials Chemistry and Physics, Vol. 294 https://doi.org/10.1016/j.matchemphys.2022.126988	journal	January 2023
Functionally graded Inconel 718 processed by additive manufacturing: Crystallographic texture, anisotropy of microstructure and mechanical properties Popovich, V. A.; Borisov, E. V.; Popovich, A. A. Materials & Design, Vol. 114 https://doi.org/10.1016/j.matdes.2016.10.075	journal	January 2017
Microstructural control during laser additive manufacturing of single-crystal nickel-base superalloys: New processing–microstructure maps involving powder feeding Liang, Yao-Jian; Cheng, Xu; Li, Jia Materials & Design, Vol. 130 https://doi.org/10.1016/j.matdes.2017.05.066	journal	September 2017
Wire + Arc Additively Manufactured Inconel 718: Effect of post-deposition heat treatments on microstructure and tensile properties Seow, Cui E.; Coules, Harry E.; Wu, Guiyi Materials & Design, Vol. 183 https://doi.org/10.1016/j.matdes.2019.108157	journal	December 2019
Columnar to equiaxed transition in additively manufactured CoCrFeMnNi high entropy alloy Li, Hongge; Huang, Yongjiang; Jiang, Songshan Materials & Design, Vol. 197 https://doi.org/10.1016/j.matdes.2020.109262	journal	January 2021
Additive manufacturing materials, methods and applications: A review Bhatia, Akash; Sehgal, Anuj Kumar Materials Today: Proceedings, Vol. 81 https://doi.org/10.1016/j.matpr.2021.04.379	journal	January 2023
Effect of heat treatment on microstructure, mechanical and corrosion properties of austenitic stainless steel 316L using arc additive manufacturing Chen, Xiaohui; Li, Jia; Cheng, Xu Materials Science and Engineering: A, Vol. 715 https://doi.org/10.1016/j.msea.2017.10.002	journal	February 2018
Identifying strain localization and dislocation processes in fatigued Inconel 718 manufactured from selective laser melting Yoo, Yung Suk Jeremy; Book, Todd A.; Sangid, Michael D. Materials Science and Engineering: A, Vol. 724 https://doi.org/10.1016/j.msea.2018.03.127	journal	May 2018
Correlation between arc mode, microstructure, and mechanical properties during wire arc additive manufacturing of 316L stainless steel Wang, Leilei; Xue, Jiaxiang; Wang, Qiang Materials Science and Engineering: A, Vol. 751 https://doi.org/10.1016/j.msea.2019.02.078	journal	March 2019
An investigation of geometrically necessary dislocations and back stress in large grained tantalum via EBSD and CPFEM Hansen, Landon T.; Fullwood, David T.; Homer, Eric R. Materials Science and Engineering: A, Vol. 772 https://doi.org/10.1016/j.msea.2019.138704	journal	January 2020
The grain size and orientation dependence of geometrically necessary dislocations in polycrystalline aluminum during monotonic deformation: Relationship to mechanical behavior Zhang, Shiqi; Liu, Wei; Wan, Jifang Materials Science and Engineering: A, Vol. 775 https://doi.org/10.1016/j.msea.2020.138939	journal	February 2020
Dissimilar metal deposition with a stainless steel and nickel-based alloy using wire and arc-based additive manufacturing Abe, Takeyuki; Sasahara, Hiroyuki Precision Engineering, Vol. 45 https://doi.org/10.1016/j.precisioneng.2016.03.016	journal	July 2016
Revealing hot tearing mechanism for an additively manufactured high-entropy alloy via selective laser melting Sun, Z.; Tan, X. P.; Descoins, M. Scripta Materialia, Vol. 168 https://doi.org/10.1016/j.scriptamat.2019.04.036	journal	July 2019
In situ site-specific specimen preparation for atom probe tomography Thompson, K.; Lawrence, D.; Larson, D. J. Ultramicroscopy, Vol. 107, Issue 2-3 https://doi.org/10.1016/j.ultramic.2006.06.008	journal	February 2007
Columnar-to-equiaxed transition in a laser scan for metal additive manufacturing Yuan, L.; Sabau, A. S.; StJohn, D. IOP Conference Series: Materials Science and Engineering, Vol. 861, Issue 1 https://doi.org/10.1088/1757-899X/861/1/012007	journal	May 2020
Fabrication of bimetallic additively manufactured structure (BAMS) of low carbon steel and 316L austenitic stainless steel with wire + arc additive manufacturing Ahsan, Md. Rumman Ul; Tanvir, Ali Newaz Mohammad; Ross, Taylor Rapid Prototyping Journal, Vol. 26, Issue 3 https://doi.org/10.1108/RPJ-09-2018-0235	journal	December 2019
Enhancement of Low-Cycle Fatigue Performance From Tailored Microstructures Enabled by Electron Beam Melting Additive Manufacturing Technology Morton, Philip A.; Mireles, Jorge; Mendoza, Heimdall Journal of Mechanical Design, Vol. 137, Issue 11 https://doi.org/10.1115/1.4031057	journal	October 2015
Formation mechanism of vermicular and lacy ferrite in austenitic stainless steel weld metals Inoue, H.; Koseki, T.; Ohkita, S. Science and Technology of Welding and Joining, Vol. 5, Issue 6 https://doi.org/10.1179/136217100101538452	journal	December 2000
Clarification on development of skeletal and lathy ferrite morphologies in stainless steel welds Brooks, J. A.; Yang, N. C. Y.; Krafcik, J. S. Science and Technology of Welding and Joining, Vol. 6, Issue 6 https://doi.org/10.1179/stw.2001.6.6.412	journal	December 2001
Solidification of a Modified Inconel 625 Alloy under Different Cooling Rates Tinoco,, José; Fredriksson,, Hasse High Temperature Materials and Processes, Vol. 23, Issue 1 https://doi.org/10.1515/HTMP.2004.23.1.13	journal	February 2004
Effect of Grain Size on the Microstructure and Strain Hardening Behavior of Solution Heat-Treated Low-C High-Mn Steel Opiela, Marek; Fojt-Dymara, Gabriela; Grajcar, Adam Materials, Vol. 13, Issue 7 https://doi.org/10.3390/ma13071489	journal	March 2020
Integration of Processing and Microstructure Models for Non-Equilibrium Solidification in Additive Manufacturing Sargent, Noah; Jones, Mason; Otis, Richard Metals, Vol. 11, Issue 4 https://doi.org/10.3390/met11040570	journal	April 2021
Functionally Graded SS 316L to Ni-Based Structures Produced by 3D Plasma Metal Deposition Rodriguez, Johnnatan; Hoefer, Kevin; Haelsig, Andre Metals, Vol. 9, Issue 6 https://doi.org/10.3390/met9060620	journal	May 2019

Similar Records

Controlling microstructure in deposits fabricated using powder blown direct energy deposition technique

Technical Report · Fri Jun 01 00:00:00 EDT 2018 · OSTI ID:1459282

A sensitivity analysis of the columnar-to-equiaxed transition for Ni-based superalloys in electron beam additive manufacturing

Journal Article · Fri Sep 07 00:00:00 EDT 2018 · Computational Materials Science · OSTI ID:1474534

Effects of lead and lean in multi-axis directed energy deposition

Journal Article · Sun Feb 12 23:00:00 EST 2023 · International Journal of Advanced Manufacturing Technology · OSTI ID:1928950

Related Subjects

36 MATERIALS SCIENCE
Deformation mechanisms
Directed energy deposition (DED)
Dislocation density
Grain morphology

Strength-ductility synergy through microstructural and compositional heterogeneity in directed energy deposition additive manufacturing of face-centered cubic materials

Citation Formats

References (47)

Similar Records

Related Subjects