Phase transformation dynamics guided alloy development for additive manufacturing

Guo, Qilin; Qu, Minglei; Chuang, Chihpin Andrew; Xiong, Lianghua; Nabaa, Ali; Young, Zachary A.; Ren, Yang; Kenesei, Peter; Zhang, Fan; Chen, Lianyi

doi:10.1016/j.addma.2022.103068

Title: Phase transformation dynamics guided alloy development for additive manufacturing

Journal Article · 01 August 2022 · Additive Manufacturing

DOI: https://doi.org/10.1016/j.addma.2022.103068 · OSTI ID:1905878

Guo, Qilin ^[1]; Qu, Minglei ^[1]; Chuang, Chihpin Andrew ^[2]; Xiong, Lianghua ^[3]; Nabaa, Ali ^[1]; Young, Zachary A. ^[1]; Ren, Yang ^[2]; Kenesei, Peter ^[2]; Zhang, Fan ^[4]; Chen, Lianyi ^[1]

Univ. of Wisconsin, Madison, WI (United States)
Argonne National Lab. (ANL), Argonne, IL (United States). X-Ray Science Division
Missouri Univ. of Science and Technology, Rolla, MO (United States)
National Inst. of Standards and Technology (NIST), Gaithersburg, MD (United States)

Fusion-based additive manufacturing technologies enable the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, the non-uniform and far-from-equilibrium heating/cooling conditions pose a significant challenge to consistently obtaining desirable phases in the as-printed parts. Here, in this study, we report a martensite stainless steel development guided by phase transformation dynamics revealed by in-situ high-speed, high-energy, high-resolution X-ray diffraction. This developed stainless steel consistently forms desired fully martensitic structure across a wide range of cooling rates (10²–10⁷ °C/s), which enables direct printing of parts with fully martensitic structure. The as-printed material exhibits a yield strength of 1157 ± 23 MPa, comparable to its wrought counterpart after precipitation-hardening heat-treatment. The as-printed property is attributed to the fully martensitic structure and the fine precipitates formed during the intrinsic heat treatment in additive manufacturing. The phase transformation dynamics guided alloy development strategy demonstrated here opens the path for developing reliable, high-performance alloys specific for additive manufacturing.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities Division; National Science Foundation (NSF); US Department of the Navy, Office of Naval Research (ONR)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 1905878

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 59; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (42)

Metallurgy, mechanistic models and machine learning in metal printing DebRoy, T.; Mukherjee, T.; Wei, H. L. Nature Reviews Materials, Vol. 6, Issue 1 https://doi.org/10.1038/s41578-020-00236-1	journal	October 2020
On the microstructure and texture evolution in 17-4 PH stainless steel during laser powder bed fusion: Towards textural design Moyle, M. S.; Haghdadi, N.; Liao, X. Z. Journal of Materials Science & Technology, Vol. 117 https://doi.org/10.1016/j.jmst.2021.12.015	journal	August 2022
Anisotropy and heterogeneity of microstructure and mechanical properties in metal additive manufacturing: A critical review Kok, Y.; Tan, X. P.; Wang, P. Materials & Design, Vol. 139 https://doi.org/10.1016/j.matdes.2017.11.021	journal	February 2018
Microstructures and Properties of 17-4 PH Stainless Steel Fabricated by Selective Laser Melting Murr, Lawrence E.; Martinez, Edwin; Hernandez, Jennifer Journal of Materials Research and Technology, Vol. 1, Issue 3 https://doi.org/10.1016/S2238-7854(12)70029-7	journal	October 2012
Development of combined microstructure and structure characterization facility for in situ and operando studies at the Advanced Photon Source Ilavsky, Jan; Zhang, Fan; Andrews, Ross N. Journal of Applied Crystallography, Vol. 51, Issue 3 https://doi.org/10.1107/S160057671800643X	journal	June 2018
Impact of DED process parameters on the metallurgical characteristics of 17-4 PH SS deposited using DED Mathoho, I.; Akinlabi, E. T.; Arthur, N. CIRP Journal of Manufacturing Science and Technology, Vol. 31 https://doi.org/10.1016/j.cirpj.2020.07.007	journal	November 2020
Processing metallic materials far from equilibrium Shahani, Ashwin J.; Clarke, Amy J. MRS Bulletin, Vol. 45, Issue 11 https://doi.org/10.1557/mrs.2020.269	journal	November 2020
Additive manufacturing (3D printing): A review of materials, methods, applications and challenges Ngo, Tuan D.; Kashani, Alireza; Imbalzano, Gabriele Composites Part B: Engineering, Vol. 143 https://doi.org/10.1016/j.compositesb.2018.02.012	journal	June 2018
Exploiting thermal strain to achieve an in-situ magnetically graded material Freeman, Felicity S. H. B.; Lincoln, Alex; Sharp, Jo Materials & Design, Vol. 161 https://doi.org/10.1016/j.matdes.2018.11.011	journal	January 2019
In-situ neutron diffraction study of wrought and selective laser melted maraging stainless steels Alnajjar, Michella; Christien, Frédéric; Bosch, Cédric Materials Characterization, Vol. 172 https://doi.org/10.1016/j.matchar.2020.110840	journal	February 2021
How Austenitic Is a Martensitic Steel Produced by Laser Powder Bed Fusion? A Cautionary Tale Zhang, Fan; Stoudt, Mark R.; Hammadi, Souzan Metals, Vol. 11, Issue 12 https://doi.org/10.3390/met11121924	journal	November 2021
Determination of Martensite Start Temperature in Engineering Steels Part I. Empirical Relations Describing the Effect of Steel Chemistry Wang, Jiajun; Wolk, Pieter J. van der; Zwaag, Sybrand van der Materials Transactions, JIM, Vol. 41, Issue 7 https://doi.org/10.2320/matertrans1989.41.761	journal	January 2000
Microscale Observation via High-Speed X-ray Diffraction of Alloy 718 During In Situ Laser Melting Oh, Seunghee A.; Lim, Rachel E.; Aroh, Joseph W. JOM, Vol. 73, Issue 1 https://doi.org/10.1007/s11837-020-04481-1	journal	November 2020
Effect of processing parameters on the fractions of martensite in 17-4 PH stainless steel fabricated by selective laser melting Hsu, Tzu-Hou; Huang, Pei-Chen; Lee, Meng-Yun Journal of Alloys and Compounds, Vol. 859 https://doi.org/10.1016/j.jallcom.2020.157758	journal	April 2021
Effect of heat treatments on microstructural evolution of additively manufactured and wrought 17-4PH stainless steel Sun, Yu; Hebert, Rainer J.; Aindow, Mark Materials & Design, Vol. 156 https://doi.org/10.1016/j.matdes.2018.07.015	journal	October 2018
Image Quality Analysis: A New Method of Characterizing Microstructures Wu, Jinghui; Wray, Peter J.; Garcia, Calixto I. ISIJ International, Vol. 45, Issue 2 https://doi.org/10.2355/isijinternational.45.254	journal	January 2005
Effects of building orientation and heat treatment on fatigue behavior of selective laser melted 17-4 PH stainless steel Yadollahi, Aref; Shamsaei, Nima; Thompson, Scott M. International Journal of Fatigue, Vol. 94 https://doi.org/10.1016/j.ijfatigue.2016.03.014	journal	January 2017
Wire + Arc Additive Manufacture of 17-4 PH stainless steel: Effect of different processing conditions on microstructure, hardness, and tensile strength Caballero, Armando; Ding, Jialuo; Ganguly, Supriyo Journal of Materials Processing Technology, Vol. 268 https://doi.org/10.1016/j.jmatprotec.2019.01.007	journal	June 2019
Laser Defocusing Effect on the Microstructure and Defects of 17-4PH Parts Additively Manufactured by SLM at a Low Energy Input Leo, Paola; Cabibbo, Marcello; Del Prete, Antonio Metals, Vol. 11, Issue 4 https://doi.org/10.3390/met11040588	journal	April 2021
Effect of heat treatment on the microstructural evolution of a nickel-based superalloy additive-manufactured by laser powder bed fusion Zhang, Fan; Levine, Lyle E.; Allen, Andrew J. Acta Materialia, Vol. 152 https://doi.org/10.1016/j.actamat.2018.03.017	journal	June 2018
Irena : tool suite for modeling and analysis of small-angle scattering Ilavsky, Jan; Jemian, Peter R. Journal of Applied Crystallography, Vol. 42, Issue 2 https://doi.org/10.1107/S0021889809002222	journal	February 2009
Influence of laser power on microstructure of laser metal deposited 17-4 ph stainless steel Adeyemi, A. A.; Akinlabi, Et; Mahamood, R. M. IOP Conference Series: Materials Science and Engineering, Vol. 225 https://doi.org/10.1088/1757-899X/225/1/012028	journal	August 2017
Microstructure and hardness studies of Inconel 718 manufactured by selective laser melting before and after solution heat treatment Tucho, Wakshum M.; Cuvillier, Priscille; Sjolyst-Kverneland, Atle Materials Science and Engineering: A, Vol. 689 https://doi.org/10.1016/j.msea.2017.02.062	journal	March 2017
Glassy Carbon as an Absolute Intensity Calibration Standard for Small-Angle Scattering Zhang, Fan; Ilavsky, Jan; Long, Gabrielle G. Metallurgical and Materials Transactions A, Vol. 41, Issue 5 https://doi.org/10.1007/s11661-009-9950-x	journal	August 2009
High-strength Damascus steel by additive manufacturing Kürnsteiner, Philipp; Wilms, Markus Benjamin; Weisheit, Andreas Nature, Vol. 582, Issue 7813 https://doi.org/10.1038/s41586-020-2409-3	journal	June 2020
Laser Powder Bed Fusion of Precipitation-Hardened Martensitic Stainless Steels: A Review Zai, Le; Zhang, Chaoqun; Wang, Yiqiang Metals, Vol. 10, Issue 2 https://doi.org/10.3390/met10020255	journal	February 2020
Aging reactions in a 17-4 PH stainless steel Hsiao, C. N.; Chiou, C. S.; Yang, J. R. Materials Chemistry and Physics, Vol. 74, Issue 2 https://doi.org/10.1016/S0254-0584(01)00460-6	journal	March 2002
Determination of Ms Temperature in Steels: A Bayesian Neural Network Model. Capdevila, C.; Caballero, F. G.; Andrés, C. García de ISIJ International, Vol. 42, Issue 8 https://doi.org/10.2355/isijinternational.42.894	journal	January 2002
Direct Observations of Sigma Phase Formation in Duplex Stainless Steels Using In-Situ Synchrotron X-Ray Diffraction Elmer, J. W.; Palmer, T. A.; Specht, E. D. Metallurgical and Materials Transactions A, Vol. 38, Issue 3 https://doi.org/10.1007/s11661-006-9076-3	journal	March 2007
Additive manufacturing and postprocessing of Ti-6Al-4V for superior mechanical properties Qian, M.; Xu, W.; Brandt, M. MRS Bulletin, Vol. 41, Issue 10 https://doi.org/10.1557/mrs.2016.215	journal	October 2016
Microstructure and Mechanical Behavior of 17-4 Precipitation Hardenable Steel Processed by Selective Laser Melting Rafi, H. Khalid; Pal, Deepankar; Patil, Nachiket Journal of Materials Engineering and Performance, Vol. 23, Issue 12 https://doi.org/10.1007/s11665-014-1226-y	journal	September 2014
Direct observation of pore formation mechanisms during LPBF additive manufacturing process and high energy density laser welding Hojjatzadeh, S. Mohammad H.; Parab, Niranjan D.; Guo, Qilin International Journal of Machine Tools and Manufacture, Vol. 153 https://doi.org/10.1016/j.ijmachtools.2020.103555	journal	June 2020
Application of EBSD to analysis of microstructures in commercial steels Ryde, L. Materials Science and Technology, Vol. 22, Issue 11 https://doi.org/10.1179/174328406X130948	journal	November 2006
Graded microstructure and mechanical properties of additive manufactured Ti–6Al–4V via electron beam melting Tan, Xipeng; Kok, Yihong; Tan, Yu Jun Acta Materialia, Vol. 97 https://doi.org/10.1016/j.actamat.2015.06.036	journal	September 2015
Metastable Austenite in 17-4 Precipitation-Hardening Stainless Steel Produced by Selective Laser Melting Facchini, Luca; Vicente, Nério; Lonardelli, Ivan Advanced Engineering Materials, Vol. 12, Issue 3 https://doi.org/10.1002/adem.200900259	journal	March 2010
Nitrogen Effects in Additively Manufactured Martensitic Stainless Steels: Conventional Thermal Processing and Comparison with Wrought Lass, Eric A.; Zhang, Fan; Campbell, Carelyn E. Metallurgical and Materials Transactions A, Vol. 51, Issue 5 https://doi.org/10.1007/s11661-020-05703-6	journal	March 2020
A critical review of powder-based additive manufacturing of ferrous alloys: Process parameters, microstructure and mechanical properties Fayazfar, Haniyeh; Salarian, Mehrnaz; Rogalsky, Allan Materials & Design, Vol. 144 https://doi.org/10.1016/j.matdes.2018.02.018	journal	April 2018
A study of microstructure, transformation mechanisms and correlation between microstructure and mechanical properties of a low alloyed TRIP steel Zaefferer, S.; Ohlert, J.; Bleck, W. Acta Materialia, Vol. 52, Issue 9 https://doi.org/10.1016/j.actamat.2004.02.044	journal	May 2004
Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction Zhao, Cang; Fezzaa, Kamel; Cunningham, Ross W. Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/s41598-017-03761-2	journal	June 2017
Sequential nucleation of phases in a 17-4PH steel: Microstructural characterisation and mechanical properties Yeli, Guma; Auger, Maria A.; Wilford, Keith Acta Materialia, Vol. 125 https://doi.org/10.1016/j.actamat.2016.11.052	journal	February 2017
Tensile Mechanical Behavior and Spall Response of a Selective Laser Melted 17-4 PH Stainless Steel Wang, Xiaofeng; Wang, Gang; Shi, Tongya Metallurgical and Materials Transactions A, Vol. 52, Issue 6 https://doi.org/10.1007/s11661-021-06229-1	journal	March 2021
Modelling of delta ferrite to austenite phase transformation kinetics in martensitic steels: Application to rapid cooling in additive manufacturing Villaret, Flore; Boulnat, Xavier; Aubry, Pascal Materialia, Vol. 18 https://doi.org/10.1016/j.mtla.2021.101157	journal	August 2021

Similar Records

Enhanced biomechanical performance of additively manufactured Ti-6Al-4V bone plates

Journal Article · 2021 · Journal of the Mechanical Behavior of Biomedical Materials · OSTI ID:1823325

Gupta, Saurabh Kumar; Shahidsha, Nagur; Bahl, Sumit; +5 more

A New Method for Low Cost Production of Titanium Alloys for Reducing Energy Consumption of Mechanical Systems

Technical Report · 2016 · OSTI ID:1250865

Fang, Z. Zak; Chandran, Ravi; Koopman, Mark

High Magnetic Field Processing - A Heat-Free Heat Treating Method

Technical Report · 2012 · OSTI ID:1049805

Ludtka, Gerard Michael; Ludtka, Gail Mackiewicz-; Wilgen, John B; +8 more

Related Subjects

36 MATERIALS SCIENCE
additive manufacturing
alloy design
high speed diffraction
laser processing
phase transformation
synchrotron X-ray diffraction
17–4 PH stainless steel

Title: Phase transformation dynamics guided alloy development for additive manufacturing

Citation Formats

References (42)

Similar Records

Related Subjects