skip to main content
DOE PAGES title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Towards an integrated experimental and computational framework for large-scale metal additive manufacturing

Abstract

Using the Metal Big Area Additive Manufacturing (MBAAM) system, a thin steel wall was manufactured from a low carbon steel wire. The wall was then characterized comprehensively by high-throughput high-energy X-ray diffraction (HEXRD), electron backscatter diffraction (EBSD), and in-situ HEXRD tensile tests. With the predicted temperature histories from the finite element-based additive manufacturing process simulations, the correlations between processing, microstructure, and properties were established. The correlation between the final microstructure with the predicted temperature history is well explained with the material’s continuous cooling transformation (CCT) diagram calculated based on the composition of low carbon steel wire. The final microstructure is dependent on the cooling rate during austenite to ferrite/bainite transformation during initial cooling and the subsequent reheating cycles. Fast cooling rate resulted in small ferrite grain size and fine bainite structure at the location closest to the base plate. Slower cooling rate at the side wall location and repeated reheating cycles to the ferrite-pearlite regions resulted in all allotriomorphic (equiaxed) ferrite with medium grain size

Authors:
 [1]; ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [1]; ORCiD logo [1];  [2];  [1]
  1. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Argonne National Lab. (ANL), Lemont, IL (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Argonne National Lab. (ANL), Argonne, IL (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office; USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities Division
OSTI Identifier:
1530073
Alternate Identifier(s):
OSTI ID: 1563055; OSTI ID: 1577109
Grant/Contract Number:  
AC05-00OR22725; AC02-06CH11357
Resource Type:
Accepted Manuscript
Journal Name:
Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing
Additional Journal Information:
Journal Volume: 761; Journal Issue: C; Journal ID: ISSN 0921-5093
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; Additive manufacturing; Modeling; Microstructure heterogeneity; CCT diagram; Strength; Uniform elongation; Post-necking elongation; microstructure heterogeneity; modeling

Citation Formats

Hu, Xiaohua, Nycz, Andrzej, Lee, Yousub, Shassere, Benjamin, Simunovic, Srdjan, Noakes, Mark, Ren, Yang, and Sun, Xin. Towards an integrated experimental and computational framework for large-scale metal additive manufacturing. United States: N. p., 2019. Web. doi:10.1016/j.msea.2019.138057.
Hu, Xiaohua, Nycz, Andrzej, Lee, Yousub, Shassere, Benjamin, Simunovic, Srdjan, Noakes, Mark, Ren, Yang, & Sun, Xin. Towards an integrated experimental and computational framework for large-scale metal additive manufacturing. United States. doi:10.1016/j.msea.2019.138057.
Hu, Xiaohua, Nycz, Andrzej, Lee, Yousub, Shassere, Benjamin, Simunovic, Srdjan, Noakes, Mark, Ren, Yang, and Sun, Xin. Fri . "Towards an integrated experimental and computational framework for large-scale metal additive manufacturing". United States. doi:10.1016/j.msea.2019.138057. https://www.osti.gov/servlets/purl/1530073.
@article{osti_1530073,
title = {Towards an integrated experimental and computational framework for large-scale metal additive manufacturing},
author = {Hu, Xiaohua and Nycz, Andrzej and Lee, Yousub and Shassere, Benjamin and Simunovic, Srdjan and Noakes, Mark and Ren, Yang and Sun, Xin},
abstractNote = {Using the Metal Big Area Additive Manufacturing (MBAAM) system, a thin steel wall was manufactured from a low carbon steel wire. The wall was then characterized comprehensively by high-throughput high-energy X-ray diffraction (HEXRD), electron backscatter diffraction (EBSD), and in-situ HEXRD tensile tests. With the predicted temperature histories from the finite element-based additive manufacturing process simulations, the correlations between processing, microstructure, and properties were established. The correlation between the final microstructure with the predicted temperature history is well explained with the material’s continuous cooling transformation (CCT) diagram calculated based on the composition of low carbon steel wire. The final microstructure is dependent on the cooling rate during austenite to ferrite/bainite transformation during initial cooling and the subsequent reheating cycles. Fast cooling rate resulted in small ferrite grain size and fine bainite structure at the location closest to the base plate. Slower cooling rate at the side wall location and repeated reheating cycles to the ferrite-pearlite regions resulted in all allotriomorphic (equiaxed) ferrite with medium grain size},
doi = {10.1016/j.msea.2019.138057},
journal = {Materials Science and Engineering. A, Structural Materials: Properties, Microstructure and Processing},
number = C,
volume = 761,
place = {United States},
year = {2019},
month = {6}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record

Citation Metrics:
Cited by: 2 works
Citation information provided by
Web of Science

Save / Share: