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  • 1.
    Gruber, H.
    et al.
    Chalmers University of Technology, Department of Industrial and Materials Science, Division of Materials and Manufacture, Gothenburg, SE-412 96, Sweden.
    Karimi Neghlani, Paria
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Hryha, E.
    Chalmers University of Technology, Department of Industrial and Materials Science, Division of Materials and Manufacture, Gothenburg, SE-412 96, Sweden.
    Nyborg, L.
    Chalmers University of Technology, Department of Industrial and Materials Science, Division of Materials and Manufacture, Gothenburg, SE-412 96, Sweden.
    Effect of Powder Recycling on the Fracture Behavior of Electron Beam Melted Alloy 7182018Ingår i: Powder Metallurgy Progress, ISSN 1335-8987, Vol. 18, nr 1, s. 40-48Artikel i tidskrift (Övrigt vetenskapligt)
    Abstract [en]

    Understanding the effect of powder feedstock alterations during multicycle additive manufacturing on the quality of built components is crucial to meet the requirements on critical parts for aerospace engine applications. In this study, powder recycling of Alloy 718 during electron beam melting was studied to understand its influence on fracture behavior of Charpy impact test bars. High resolution scanning electron microscopy was employed for fracture surface analysis on test bars produced from virgin and recycled powder. For all investigated samples, an intergranular type of fracture, initiated by non-metallic phases and bonding defects, was typically observed in the regions close to or within the contour zone. The fracture mode in the bulk of the samples was mainly moderately ductile dimple fracture. The results show a clear correlation between powder degradation during multi-cycle powder reuse and the amount of damage relevant defects observed on the fracture surfaces. In particular, samples produced from recycled powder show a significant amount of aluminum-rich oxide defects, originating from aluminum-rich oxide particulates on the surface of the recycled powder. © 2018 H. Gruber et al., published by Sciendo.

  • 2.
    Karimi Neghlani, Paria
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Electron beam melting of Alloy 718: Influence of process parameters on the microstructure2018Licentiatavhandling, sammanläggning (Övrigt vetenskapligt)
    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.

  • 3.
    Karimi Neghlani, Paria
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Deng, Dunyong
    Linköping University, Division of Engineering Materials, Linköping, Sweden.
    Sadeghimeresht, Esmaeil
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Olsson, Jonas
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Ålgårdh, Joakim
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). Swerea KIMAB AB, Kista, Sweden.
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Microstructure Development in Track-by-Track Melting of EBM-Manufactured Alloy 7182018Ingår i: Proceedings of the 9th International Symposium on Superalloy 718 & Derivatives: Energy, Aerospace, and Industrial Applications / [ed] Ott, E., Liu, X., Andersson, J., Bi, Z., Bockenstedt, K., Dempster, I., Groh, J., Heck, K., Jablonski, P., Kaplan, M., Nagahama, D. and Sudbrack, C., Springer, 2018, s. 643-654Konferensbidrag (Refereegranskat)
    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.

  • 4.
    Karimi Neghlani, Paria
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Raza, Tahira
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Svensson, Lars-Erik
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Influence of laser exposure time and point distance on 75-μm-thick layer of selective laser melted Alloy 7182018Ingår i: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 94, nr 5-8, s. 2199-2207Artikel i tidskrift (Refereegranskat)
    Abstract [en]

    A systematic matrix with 25 samples, using five different point distances and five laser exposure times, depositing 75-μm-thick layers of Alloy 718 has been studied. The work has concentrated on defects formed, hardness of the deposits, and the microstructure. Relatively large amount of defects, both lack of fusion and porosity, was found in several of the specimens in the deposits. The defects were never possible to fully eliminate, but a significant decrease, mainly in the lack of fusion, was seen with increasing laser exposure time. The gas porosity on the other hand was not affected to any larger degree, except for the lowest laser energy input, where a slight increase in porosity was seen. A small increase in hardness was noted with increasing laser energy input. The width of the deposited beads increased with increasing laser energy, while the depth of deposits was more or less constant. However, for the lowest combination of point distance and laser exposure time, quite deep and narrow beads were formed. A comparison was made with deposition of 50-μm-thick layers, with quite similar laser energy input, but with some variation in detailed deposition parameters. It was found that the 75-μm-thick layers contained less lack of fusion, particularly for small point distances. The amount of porosity was also less, but that did not vary with deposition parameters.© 2017 The Author(s)

  • 5.
    Karimi Neghlani, Paria
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Sadeghi, Esmaeil
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Ålgårdh, Joakim
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). Powder Materials & Additive Manufacturing, Swerea KIMAB AB, Kista, 164 40, Sweden.
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    EBM-manufactured single tracks of Alloy 718: Influence of energy input and focus offset on geometrical and microstructural characteristics2019Ingår i: Materials Characterization, ISSN 1044-5803, E-ISSN 1873-4189, Vol. 148, s. 88-99Artikel i tidskrift (Refereegranskat)
    Abstract [en]

    Electron beam melting-powder bed fusion (EBM-PBF) is an additive manufacturing process, which is able to produce parts in layer-by-layer fashion from a 3D model data. Currently application of this technology in parts manufacturing with high geometrical complexity has acquired growing interest in industry. To recommend the EBM process into industry for manufacturing parts, improved mechanical properties of final part must be obtained. Such properties highly depend on individual single melted track and single layer. In EBM, interactions between the electron beam, powder, and solid underlying layer affect the geometrical (e.g., re-melt depth, track width, contact angle, and track height) and microstructural (e.g., grain structure, and primary dendrite arm spacing) characteristics of the melted tracks. The core of the present research was to explore the influence of linear energy input parameters in terms of beam scanning speed, beam current as well as focus offset and their interactions on the geometry and microstructure of EBM-manufactured single tracks of Alloy 718. Increased scanning speed led to lower linear energy input values (<0.9 J/mm) in an specific range of the focus offset (0–10 mA) which resulted in instability, and discontinuity of the single tracks as well as balling effect. Decreasing the scanning speed and increasing the beam current resulted in higher melt pool depth and width. By statistical evaluations, the most influencing parameters on the geometrical features were primarily the scanning speed, and secondly the beam current. Primary dendrite arm spacing (PDAS) slightly decreased by increasing the scanning speed using lower beam current values as the linear energy input decreased. By increasing the linear energy input, the chance of more equiaxed grain formation was high, however, at lower linear energy input, mainly columnar grains were observed. The lower focus offset values resulted in more uniform grains along the 〈001〉 crystallographic direction. © 2018 Elsevier Inc. 

  • 6.
    Karimi Neghlani, Paria
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Sadeghimeresht, Esmaeil
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Deng, D.
    Linköping University, Division of Engineering Materials, Department of Management and Engineering, Linköping, 581 83, Sweden.
    Gruber, H.
    University of Chalmers, Division of Materials and Manufacture, Industrial and Materials Science, Gothenburg, 412 96, Sweden.
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Nylen, Per
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Influence of build layout and orientation on microstructural characteristics of electron beam melted Alloy 7182018Ingår i: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 99, nr S1, s. 2903-2913Artikel i tidskrift (Refereegranskat)
    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).

  • 7.
    Karimi Neghlani, Paria
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Sadeghimeresht, Esmaeil
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Åkerfeldt, Pia
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Luleå, 971 87, Sweden.
    Ålgårdh, Joakim
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT). Powder Materials & Additive Manufacturing, Swerea KIMAB AB, Kista, 164 40, Sweden.
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Influence of successive thermal cycling on microstructure evolution of EBM-manufactured alloy 718 in track-by-track and layer-by-layer design2018Ingår i: Materials & design, ISSN 0264-1275, E-ISSN 1873-4197, Vol. 160, s. 427-441Artikel i tidskrift (Refereegranskat)
    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

  • 8.
    Karimineghlani, Parvin
    et al.
    Texas A&M University, Department of Material Science and Engineering, College Station, TX 77843, USA.
    Karimi Neghlani, Paria
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Azadmehr, Amirreza
    Amirkabir University of Technology, Department of Mining and Metallurgical Engineering,Tehran, Iran, 15875-4413.
    Optimization of lead ions adsorption on hydrolyzed polyacrylonitrile fibers using central composite design2017Ingår i: Desalination and Water Treatment, ISSN 1944-3994, E-ISSN 1944-3986, Vol. 83, s. 133-143Artikel i tidskrift (Refereegranskat)
    Abstract [en]

    Optimization of lead ions (Pb++) adsorption on the hydrolyzed polyacrylonitrile (PAN) fibers was reported by using statistical approach. Electrospinning of PAN solutions in dimethylformamide (DMF) was performed with different concentrations. The electrospun fibres, with various diame-ters, were then hydrolyzed in a sodium hydroxide solution (NaOH) for different reaction times and temperatures. Response surface methodology (RSM) helped optimizing the hydrolysis reaction con-ditions to maximize the adsorption capacity of the PAN fibers. The maximum value of adsorption capacity was experimentally determined to be 141 mg/g with the optimized values of hydrolysis reaction time, temperature and fiber diameter being 61.6°C, 82.1 min and 280 nm, respectively. The as-prepared electrospun fibers, hydrolyzed fibers and fibers after adsorption process were charac-terized by scanning electron microscope (SEM). Experimental adsorption data fit very well with the Langmuir isotherm model. It was found that Pb++ ions adsorption on the nanofibers was 20 times higher than that on microfibers under the same conditions. Adsorption kinetics followed the second order kinetics model. © 2017 Desalination Publications. All rights reserved.

  • 9.
    Sadeghi, Esmaeil
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Karimi Neghlani, Paria
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Momeni, Soroush
    Friedrich-Alexander University Erlangen-Nurnberg, Department of Materials Science and Engineering, Erlangen, 91058, Germany.
    Seifi, Mohsen
    Case Western Reserves University, Department of Materials Science & Engineering, Cleveland, 44106,USA; ASTM International, Washington, DC 20036, United States .
    Eklund, Anders
    Quintus Technologies AB, Västerås, 721 66, Sweden.
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Influence of thermal post treatments on microstructure and oxidation behavior of EB-PBF manufactured Alloy 7182019Ingår i: Materials Characterization, ISSN 1044-5803, E-ISSN 1873-4189, Vol. 150, s. 236-251Artikel i tidskrift (Refereegranskat)
    Abstract [en]

    The effect of thermal post treatments consisting of heat treatment (HT), hot isostatic pressing (HIP), and combined HIP-HT on microstructure and oxidation behavior of Alloy 718 manufactured by electron beam powder bed fusion (EB-PBF) technique was investigated. Oxidation of the as-built and post-treated specimens was performed in ambient air at 650, 750, and 850 °C for up to 168 h. Directional columnar-grained microstructure, pores and fine Nb-rich carbides were observed in the as-built specimen. The HT specimen presented the columnar microstructure, plate-like δ phase at grain boundaries, and pores. The dominant grain crystallographic orientation was changed from 〈001〉 in the as-built specimen to 〈101〉 after HT. No grain boundary δ phase was observed in the HIPed specimen, but recrystallization occurred in both the HIP and HIP-HT specimens due to a rapid cooling after HIPing motivating the nucleation of fine grains with limited time to grow. After oxidation exposure at 650 and 750 °C for 168 h, no big difference between weight changes of the as-built and post-treated specimens was noted, whereas at 850 °C, the combined HIP-HT specimen showed the most promising corrosion resistance with the least weight change. At 850 °C, a protective scale of Cr 2 O 3 rich in Cr, Ti, and Ni as well as an internal oxide (branched structure of alumina) developed in all the specimens, while, only a protective Cr 2 O 3 scale was found at 650 and 750 °C. The HIP-HT specimen at 850 °C developed an oxide scale, which was denser and more adherent in comparison to the oxide scales formed on the other three specimens, associated with its limited defect distribution and more homogenized microstructure. Moreover, the δ phase formed close to the surface of the exposed specimens during the oxidation exposure at 850 °C most probably led to nucleation and growth of the oxide scale. © 2019 Elsevier Inc.

  • 10.
    Sadeghimeresht, Esmaeil
    et al.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Karimi Neghlani, Paria
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för avverkande och additativa tillverkningsprocesser (AAT).
    Zhang, Pimin
    Linköping University,Department of Management and Engineering, Linköping, Sweden.
    Peng, Ru
    Linköping University,Department of Management and Engineering, Linköping, Sweden.
    Andersson, Joel
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Avdelningen för svetsteknologi (SV).
    Pejryd, Lars
    Örebro University, School of Science and Technology, Örebro, Sweden.
    Joshi, Shrikant V.
    Högskolan Väst, Institutionen för ingenjörsvetenskap, Forskningsmiljön produktionsteknik(PTW).
    Isothermal Oxidation Behavior of EBM-Additive Manufactured Alloy 7182018Ingår i: Proceedings of the 9th International Symposium on Superalloy 718 & Derivatives: Energy, Aerospace, and Industrial Applications / [ed] Ott, E., Liu, X., Andersson, J., Bi, Z., Bockenstedt, K., Dempster, I., Groh, J., Heck, K., Jablonski, P., Kaplan, M., Nagahama, D. and Sudbrack, C., Springer, 2018, s. 219-240Konferensbidrag (Refereegranskat)
    Abstract [en]

    Oxidation of Alloy 718 manufactured by electron beam melting (EBM) process has been undertaken in ambient air at 650, 700, and 800 °C for up to 168 h. At 800 °C, a continuous external chromia oxide enriched in (Cr, Ti, Mn, Ni) and an internal oxide that was branched structure of alumina formed, whereas at 650 and 700 °C, a continuous, thin and protective chromia layer was detected. The oxidation kinetics of the exposed EBM Alloy 718 followed the parabolic rate law with an effective activation energy of ~248 ± 22 kJ/mol in good agreement with values in the literature for conventionally processed chromia-forming Ni-based superalloys. The oxide scale formed on the surface perpendicular to the build direction was slightly thicker, and more adherent compared to the scale formed on the surface along the build direction, attributed to the varied grain texture in the two directions of the EBM-manufactured specimens. The increased oxygen diffusion and high Cr depletion found on the surface along the build direction were attributed to the fine grains and formation of vacancies/voids along this grain orientation.

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