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Electron beam melting of Alloy 718: Influence of process parameters on the microstructure
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0001-6610-1486
2018 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Additive manufacturing (AM) is the name given to the technology of building 3D parts by adding layer-by-layer of materials, including metals, plastics, concrete, etc. Of the different types of AM techniques, electron beam melting (EBM), as a powder bed fusion technology, has been used in this study. EBM is used to build parts by melting metallic powders by using a highly intense electron beam as the energy source. Compared to a conventional process, EBM offers enhanced efficiency for the production of customized and specific parts in aerospace, space, and medical fields. In addition, the EBM process is used to produce complex parts for which other technologies would be either expensive or difficult to apply. This thesis has been divided into three sections, starting from a wider window and proceeding to a smaller one. The first section reveals how the position-related parameters (distance between samples, height from build plate, and sample location on build plate) can affect the microstructural characteristics. It has been found that the gap between the samples and the height from the build plate can have significant effects on the defect content and niobium-rich phase fraction. In the second section, through a deeper investigation, the behavior of Alloy 718 during the EBM process as a function of different geometry-related parameters is examined by building single tracks adjacent to each other (track-by-track) andsingle-wall samples (single tracks on top of each other). In this section, the main focus is to understand the effect of successive thermal cycling on microstructural evolution. In the final section, the correlations between the main machine-related parameters (scanning speed, beam current, and focus offset) and the geometrical (melt pool width, track height, re-melted depth, and contact angle) and microstructural (grain structure, niobium-rich phase fraction, and primary dendrite arm spacing) characteristics of a single track of Alloy 718 have been investigated. It has been found that the most influential machine-related parameters are scanning speed and beam current, which have significant effects on the geometry and the microstructure of the single-melted tracks.

Place, publisher, year, edition, pages
Trollhättan: University West , 2018. , p. 65
Series
Licentiate Thesis: University West ; 22
Keywords [en]
Additive manufacturing; Powder bed fusion; Electron beam melting; Part’s orientation; Microstructure development; Single track; Energy input; Focus offset; Geometrical features, Alloy 718
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-13140ISBN: 978-91-88847-08-9 (print)ISBN: 978-91-88847-07-2 (electronic)OAI: oai:DiVA.org:hv-13140DiVA, id: diva2:1264207
Presentation
2018-11-21, C120, Högskolan Väst, Trollhättan, 10:00 (English)
Supervisors
Available from: 2018-11-21 Created: 2018-11-19 Last updated: 2018-11-19
List of papers
1. Influence of successive thermal cycling on microstructure evolution of EBM-manufactured alloy 718 in track-by-track and layer-by-layer design
Open this publication in new window or tab >>Influence of successive thermal cycling on microstructure evolution of EBM-manufactured alloy 718 in track-by-track and layer-by-layer design
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2018 (English)In: Materials & design, ISSN 0264-1275, E-ISSN 1873-4197, Vol. 160, p. 427-441Article in journal (Refereed) Published
Abstract [en]

Successive thermal cycling (STC) during multi-track and multi-layer manufacturing of Alloy 718 using electron beam melting (EBM) process leads to a microstructure with a high degree of complexity. In the present study, a detailed microstructural study of EBM-manufactured Alloy 718 was conducted by producing samples in shapes from one single track and single wall to 3D samples with maximum 10 longitudinal tracks and 50 vertical layers. The relationship between STC, solidification microstructure, interdendritic segregation, phase precipitation (MC, δ-phase), and hardness was investigated. Cooling rates (liquid-to-solid and solid-to-solid state) was estimated by measuring primary dendrite arm spacing (PDAS) and showed an increased cooling rate at the bottom compared to the top of the multi-layer samples. Thus, microstructure gradient was identified along the build direction. Moreover, extensive formation of solidification micro-constituents including MC-type carbides, induced by micro-segregation, was observed in all the samples. The electron backscatter diffraction (EBSD) technique showed a high textured structure in 〈001〉 direction with a few grains misoriented at the surface of all samples. Finer microstructure and possibility of more γ″ phase precipitation at the bottom of the samples resulted in slightly higher (~11%) hardness values compared to top of the samples. © 2018 Elsevier Ltd

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
3D printers; Carbides; Cooling; Electron beam melting; Electron beams; Hardness; Segregation (metallography); Solidification; Thermal cycling, Alloy 718; Electron backscatter diffraction technique; Interdendritic segregation; Layer by layer; Micro-structure evolutions; Primary dendrite arm spacings; Solidification microstructures; Track by track, Microstructure
National Category
Manufacturing, Surface and Joining Technology Metallurgy and Metallic Materials
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
urn:nbn:se:hv:diva-13042 (URN)10.1016/j.matdes.2018.09.038 (DOI)2-s2.0-85053828514 (Scopus ID)
Available from: 2018-10-29 Created: 2018-10-29 Last updated: 2018-11-19Bibliographically approved
2. Influence of build layout and orientation on microstructural characteristics of electron beam melted Alloy 718
Open this publication in new window or tab >>Influence of build layout and orientation on microstructural characteristics of electron beam melted Alloy 718
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2018 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015Article in journal (Refereed) Epub ahead of print
Abstract [en]

Effects of build layout and orientation consisting of (a) height from the build plate (Z-axis), (b) distance between samples, and (c) location in the build plate (X-Y plane) on porosity, NbC fraction, and hardness in electron beam melted (EBM) Alloy 718 were studied. The as-built samples predominantly showed columnar structure with strong ˂001˃ crystallographic orientation parallel to the build direction, as well as NbC and ÎŽ-phase in inter-dendrites and grain boundaries. These microstructural characteristics were correlated with the thermal history, specifically cooling rate, resulted from the build layout and orientation parameters. The hardness and NbC fraction of the samples increased around 6% and 116%, respectively, as the height increased from 2 to 45 mm. Moreover, by increasing the height, formation of ÎŽ-phase was also enhanced associated with lower cooling rate in the samples built with a greater distance from the build plate. However, the porosity fraction was unaffected. Increasing the sample gap from 2 to 10 mm did not change the NbC fraction and hardness; however, the porosity fraction increased by 94%. The sample location in the build chamber influenced the porosity fraction, particularly in interior and exterior areas of the build plate. The hardness and NbC fraction were not dependent on the sample location in the build chamber. © 2018, The Author(s).

Place, publisher, year, edition, pages
Springer, 2018
Keywords
3D printers, Cooling, Electron beam melting, Electron beams, Grain boundaries, Hardness, Location, Niobium compounds, Porosity, Alloy 718, Build direction, Columnar structures, Crystallographic orientations, Micro-structural characteristics, Micro-structural characterization, Orientation parameter, Sample location, Porous plates
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
urn:nbn:se:hv:diva-13043 (URN)10.1007/s00170-018-2621-6 (DOI)2-s2.0-85053670925 (Scopus ID)
Note

First Online: 17 September 2018

Available from: 2018-10-29 Created: 2018-10-29 Last updated: 2018-11-19Bibliographically approved
3. Microstructure Development in Track-by-Track Melting of EBM-Manufactured Alloy 718
Open this publication in new window or tab >>Microstructure Development in Track-by-Track Melting of EBM-Manufactured Alloy 718
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2018 (English)In: Proceedings of the 9th International Symposium on Superalloy 718 & Derivatives: Energy, Aerospace, and Industrial Applications, 2018, p. 643-654Conference paper, Published paper (Refereed)
Abstract [en]

Electron beam melting (EBM) is a powder-bed fusion process within the group of additive manufacturing (AM) technology that is used to fabricate high performance metallic parts. Nickel-Iron base superalloys, such as Alloy 718, are subjected to successive heating and cooling at temperatures in excess of 800 °C during the EBM process. Characterization of the dendritic structure, carbides, Laves and δ-phase were of particular interest in this study. These successive thermal cycles influence the microstructure of the material resulting in a heterogeneous structure, especially in the building direction. Hence, the aim of this study was to gain increased fundamental understanding of the relationship between the processing history and the microstructure formed within a single layer. Different numbers of tracks with equal heights were for this purpose produced, varying from one to ten tracks. All tracks used the same process parameters regardless of number and/or position. Microstructure characteristics (sub-grain structure, grain structure and phases) were analyzed by optical microscopy, scanning electron microscopy equipped with energy disperse spectroscopy and electron backscatter diffraction. The direction of dendrites changed in the overlap zones within the tracks due to re-melting of material in the overlap zone. The primary dendrite arm spacings slightly increased along multi-tracks owing to a slight decrease in cooling rate by addition of the next tracks. Epitaxial growth of grains were observed in all samples due to partial re-melting of grains in previous layers and surface nucleation was also found to occur in all tracks.

Series
The Minerals, Metals & Materials Series, ISSN 2367-1181, E-ISSN 2367-1696
Keywords
Additive manufacturin, g Electron beam melting, Alloy 718, Microstructure, Track-by-Track
National Category
Metallurgy and Metallic Materials Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
urn:nbn:se:hv:diva-12345 (URN)10.1007/978-3-319-89480-5_42 (DOI)978-3-319-89479-9 (ISBN)
Conference
9th International Symposium on Superalloy 718 & Derivatives, Energy, Aerospace, and Industrial Applications
Note

First Online: 13 May 2018

Available from: 2018-10-26 Created: 2018-10-26 Last updated: 2018-11-19Bibliographically approved

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Karimi Neghlani, Paria

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