Correlations of cracking with scan strategy and build geometry in electron beam powder bed additive manufacturing
[1];
[2];
[4]
- Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Computational Sciences and Engineering Division; Oak Ridge National Lab. (ORNL), Knoxville, TN (United States). Manufacturing Demonstration Facility
- Oak Ridge National Lab. (ORNL), Knoxville, TN (United States). Manufacturing Demonstration Facility; Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Materials Science & Technology Division
- Oak Ridge National Lab. (ORNL), Knoxville, TN (United States). Manufacturing Demonstration Facility
- Oak Ridge National Lab. (ORNL), Knoxville, TN (United States). Manufacturing Demonstration Facility; Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Electrical and Electronics Systems Research Division
The extension of metal additive manufacturing (AM) to non-weldable Ni-based superalloys remains a challenge for the electron beam melting process. Various cracking mechanisms, including solidification, liquation, strain-age, and ductility dip cracking, make it difficult to fabricate traditionally non-weldable Ni-based superalloys using the AM process. Because airfoil geometries are highly complicated, the correspondingly complex thermal signatures lead to various types of cracking in geometries that are under severe mechanical restraints during the printing process. This work aims to understand the correlations between cracking, scan strategy, and part geometry in airfoil geometries. Crack locations were monitored via an in-situ near-infrared camera during printing. A part-scale finite element method (FEM) was used to reveal cracking mechanisms. New scan strategies that avoided cracking were utilized in an FEM simulation. Here, the present work demonstrates the potential for scan strategy optimization to manipulate stress distribution and the resultant microstructure of parts for industrial applications.
- Research Organization:
- Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
- Sponsoring Organization:
- USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office (EE-5A)
- Grant/Contract Number:
- AC05-00OR22725
- OSTI ID:
- 1607045
- Journal Information:
- Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: C Vol. 32; ISSN 2214-8604
- Publisher:
- ElsevierCopyright Statement
- Country of Publication:
- United States
- Language:
- English
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