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Title: Evaluation of an Al-Ce alloy for laser additive manufacturing

Our present research in metal additive manufacturing (AM) focuses on designing processing parameters around existing alloys designed for traditional manufacturing. However, to maximize the benefits of AM, alloys should be designed to specifically take advantage of the unique thermal conditions of these processes. Furthermore, our study focuses on the development of a design methodology for alloys in AM, using a newly developed Al-Ce alloy as an initial case study. To evaluate the candidacy of this system for fusion based additive manufacturing, single-line laser melts were made on cast Al-12Ce plates using three different beam velocities (100, 200, and 300 mm/min). The microstructure was evaluated in the as-melted and heat treated conditions (24 hrs at 300°C). An extremely fine microstructure was observed within the weld pools, evolving from eutectic at the outer solid-liquid boundaries to a primary Al FCC dendritic/cellular structure nearer the melt-pool centerline. We rationalized the observed microstructures through the construction of a microstructure selection map for the Al-Ce binary system, which will be used to enable future alloy design. Interestingly, the heat treated samples exhibited no microstructural coarsening.
Authors:
 [1] ;  [2] ;  [2] ;  [3] ;  [2] ;  [4] ;  [2] ;  [1] ;  [5]
  1. Univ. of Tennessee, Knoxville, TN (United States). Dept. of Mechanical Aerospace and Biomedical Engineering
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility and Materials Science and Technology Division
  3. Univ. of Tennessee, Knoxville, TN (United States). Bredesen Center for Interdisciplinary Research
  4. Ames Lab., Ames, IA (United States). Divison of Materials Science and Engineering
  5. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility and Energy and Transportation Science Division
Publication Date:
Grant/Contract Number:
AC05-00OR22725
Type:
Accepted Manuscript
Journal Name:
Acta Materialia
Additional Journal Information:
Journal Volume: 126; Journal Issue: C; Journal ID: ISSN 1359-6454
Publisher:
Elsevier
Research Org:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). High Temperature Materials Lab. (HTML); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)
Sponsoring Org:
USDOE
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; Additive manufacturing; Al alloys; Microstructure control; Microstructure modeling
OSTI Identifier:
1347317
Alternate Identifier(s):
OSTI ID: 1397786

Plotkowski, A., Rios, O., Sridharan, N., Sims, Z., Unocic, K., Ott, R. T., Dehoff, R. R., Babu, S. S., and Oak Ridge National Lab.. Evaluation of an Al-Ce alloy for laser additive manufacturing. United States: N. p., Web. doi:10.1016/j.actamat.2016.12.065.
Plotkowski, A., Rios, O., Sridharan, N., Sims, Z., Unocic, K., Ott, R. T., Dehoff, R. R., Babu, S. S., & Oak Ridge National Lab.. Evaluation of an Al-Ce alloy for laser additive manufacturing. United States. doi:10.1016/j.actamat.2016.12.065.
Plotkowski, A., Rios, O., Sridharan, N., Sims, Z., Unocic, K., Ott, R. T., Dehoff, R. R., Babu, S. S., and Oak Ridge National Lab.. 2016. "Evaluation of an Al-Ce alloy for laser additive manufacturing". United States. doi:10.1016/j.actamat.2016.12.065. https://www.osti.gov/servlets/purl/1347317.
@article{osti_1347317,
title = {Evaluation of an Al-Ce alloy for laser additive manufacturing},
author = {Plotkowski, A. and Rios, O. and Sridharan, N. and Sims, Z. and Unocic, K. and Ott, R. T. and Dehoff, R. R. and Babu, S. S. and Oak Ridge National Lab.},
abstractNote = {Our present research in metal additive manufacturing (AM) focuses on designing processing parameters around existing alloys designed for traditional manufacturing. However, to maximize the benefits of AM, alloys should be designed to specifically take advantage of the unique thermal conditions of these processes. Furthermore, our study focuses on the development of a design methodology for alloys in AM, using a newly developed Al-Ce alloy as an initial case study. To evaluate the candidacy of this system for fusion based additive manufacturing, single-line laser melts were made on cast Al-12Ce plates using three different beam velocities (100, 200, and 300 mm/min). The microstructure was evaluated in the as-melted and heat treated conditions (24 hrs at 300°C). An extremely fine microstructure was observed within the weld pools, evolving from eutectic at the outer solid-liquid boundaries to a primary Al FCC dendritic/cellular structure nearer the melt-pool centerline. We rationalized the observed microstructures through the construction of a microstructure selection map for the Al-Ce binary system, which will be used to enable future alloy design. Interestingly, the heat treated samples exhibited no microstructural coarsening.},
doi = {10.1016/j.actamat.2016.12.065},
journal = {Acta Materialia},
number = C,
volume = 126,
place = {United States},
year = {2016},
month = {12}
}