journal article·2020-03

Scheil ternary projection (STeP) diagrams for designing additively manufactured functionally graded metals

Abdel R. Moustafa, A. Durga, Greta Lindwall, Zachary C. Cordero

Publisher page

Abstract

Functionally graded metals fabricated using high-temperature additive manufacturing can form intermetallics that fracture during printing due to thermal stresses generated by the heat source. To address this problem, we introduce a new class of non-equilibrium phase diagrams, termed Scheil Ternary Projection (STeP) diagrams, for designing optimal composition gradients that avoid brittle phases. Using the Fe-Cr-Al ternary as a model system, we compare the phase fields in equilibrium and STeP diagrams to show that intermetallic phase fields are dramatically expanded under the rapid solidification conditions in melt-based additive manufacturing, an important effect that must be accounted for when designing composition gradients.
Source: expertdata · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Intermetallics and Advanced Alloy Properties

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (61)

Show source-provided references
1. Gradients in composite materials10.1007/BF00549902 ↗
2. Recent development status of functionally gradient materials10.2355/isijinternational.30.699 ↗
3. Concept and P/M fabrication of functionally gradient materials10.1016/0272-8842(95)00143-3 ↗
4. Compositionally graded metals : a new frontier of additive manufacturing10.1557/jmr.2014.208 ↗
5. Developing gradient metal alloys through radial deposition additive manufacturing10.1038/srep05357 ↗
6. Fabrication of Fe-FeAl functionally graded material using the wire-arc additive manufacturing process10.1007/s11663-015-0509-5 ↗
7. Selective laser melting of tungsten-copper functionally graded material10.1016/j.matlet.2018.11.127 ↗
8. Additive manufacturing of functionally graded metallic materials using laser metal deposition
9. Additive manufacturing of a functionally graded material from Ti-6Al-4V to Invar : experimental characterization and thermodynamic calculations10.1016/j.actamat.2016.12.070 ↗
10. Computational design of gradient paths in additively manufactured functionally graded materials10.1115/1.4040816 ↗
11. Functionally graded materials through robotics-inspired path planning10.1016/j.matdes.2019.107975 ↗
12. Model for solute redistribution during rapid solidification10.1063/1.329867 ↗
13. Solute Trapping : comparison of theory with experiment10.1103/PhysRevLett.56.2489 ↗
14. Thermal process maps for predicting solidification microstructure in laser fabrication of thin-wall structures10.1016/j.jmatprotec.2006.03.155 ↗
15. Integrated control of solidification microstructure and melt pool dimensions in electron beam wire feed additive manufacturing of Ti-6Al-4V
16. Poirier · 2016
17. Bemerkungen zur schichtkristallbildung
18. Application of finite element, phase-field, and CALPHAD-based methods to additive manufacturing of Ni-based superalloys10.1016/j.actamat.2017.05.003 ↗
19. Additive manufacturing of 17-4 PH stainless steel : post-processing heat treatment to achieve uniform reproducible microstructure10.1007/s11837-015-1754-4 ↗
20. THERMO-CALC & DICTRA, computational tools for materials science10.1016/S0364-5916(02)00037-8 ↗
21. TCHEA1: a thermodynamic database not limited for “high entropy” alloys10.1007/s11669-017-0570-7 ↗
22. Database development and Calphad calculations for high entropy alloys: challenges, strategies, and tips10.1016/j.matchemphys.2017.07.082 ↗
23. Chemically graded Fe–Al/steel samples fabricated by laser metal deposition10.1557/adv.2017.124 ↗
24. Intermetallics synthesis in the Fe–Al system via layer by layer 3D laser cladding10.3390/cryst3040517 ↗
25. Fabrication of iron-rich Fe–Al intermetallics using the wire-arc additive manufacturing process
26. Laser metal deposition and selective laser melting of Fe–28 at.% Al10.1557/jmr.2014.131 ↗
27. Structure and properties of the Fe 3 Al-type intermetallic alloy fabricated by laser engineered net shaping (LENS)10.1016/j.msea.2015.10.076 ↗
28. Fabrication of Fe-Cr-Al oxide dispersion strengthened PM2000 alloy using selective laser melting10.1002/adem.200800407 ↗
29. Selective laser sintering of MA956 oxide dispersion strengthened steel
30. Materials characterisation of a complex thin walled structure fabricated by selective laser melting using a ferritic oxide dispersion strengthened steel10.1016/j.matchar.2015.11.021 ↗
31. Elaboration of oxide dispersion strengthened Fe-14Cr stainless steel by selective laser melting10.1016/j.jmatprotec.2018.12.034 ↗
32. Fabrication and microstructure characterization of selevtive laser-melted FeAl intermetallic parts10.1016/j.surfcoat.2012.05.072 ↗
33. Development of functionally graded materials by ultrasonic consolidation, CIRP10.1016/j.cirpj.2010.07.006 ↗
34. Damage-tolerant metallic composites via melt infiltration of additively manufactured preforms10.1016/j.matdes.2017.04.072 ↗
35. Mesostructure and porosity effects on the thermal conductivity of additively manufactured interpenetrating phase composites
36. Hypervelocity impact of PrintCast A356/316L composites
37. Additive manufacturing of advanced multi-component alloys: bulk metallic glasses and high entropy alloys10.1002/adem.201700874 ↗
38. Microstructure and phase evolution in laser rapid forming of a functionally graded Ti – Rene88DT alloy10.1016/j.actamat.2005.12.019 ↗
39. Microstructure and mechanical behavior of commercial purity Ti/Ti–6Al–2Zr–1Mo–1V structurally graded material fabricated by laser additive manufacturing10.1016/j.scriptamat.2013.11.002 ↗
40. Laser deposition of compositionally graded titanium-vanadium and titanium-molybdenum alloys10.1016/S0921-5093(02)00909-7 ↗
41. An application of differential injection to fabricate functionally graded Ti- Nb alloys using DED-CLAD process10.1016/j.jmatprotec.2019.01.018 ↗
42. Fabrication of functionally graded TiC/Ti composites by laser engineered net shaping10.1016/S1359-6462(03)00020-4 ↗
43. Laser metal deposition of functionally graded Ti6Al4V/TiC10.1016/j.matdes.2015.06.135 ↗
44. Compositionally graded Ti6Al4V + TiC made by direct laser fabrication using powder and wire10.1016/j.matdes.2006.06.010 ↗
45. Development and characterization of Ti-6Al-4V to 304L stainless steel gradient components fabricated with laser deposition additive manufacturing10.1016/j.matdes.2016.05.016 ↗
46. Characterization of a functionally graded material of Ti-6Al-4V to 304L stainless steel with an intermediate V section10.1016/j.jallcom.2018.01.156 ↗
47. Stainless steel to titanium bimetallic structure using LENSTM
48. Analysis of formation and growth of the σ phase in additively manufactured functionally graded materials10.1016/j.jallcom.2019.151729 ↗
49. Functionally graded Ti6Al4V-Mo alloy manufactured with DED-CLAD process
50. Multiscale study of different types of interface of a buffer material in powder-based directed energy deposition : example of Ti6Al4V / Ti6Al4V - Mo/Mo - Inconel 718
51. Functionally graded material of 304L stainless steel and inconel 625 fabricated by directed energy deposition: characterization and thermodynamic modeling10.1016/j.actamat.2016.02.019 ↗
52. Evaluation for mechanical characteristics of Inconel625–SUS316L joint produced with direct energy deposition10.1016/j.promfg.2017.11.012 ↗
53. Parametric study of development of Inconel-steel functionally graded materials by laser direct metal deposition10.1016/j.matdes.2013.08.079 ↗
54. Laser rapid forming of SS316L/Rene88DT graded material10.1016/j.msea.2004.08.072 ↗
55. Phase formation and microstructure evolution in laser rapid forming of graded SS316L/Rene88DT alloy10.1016/j.msea.2005.05.024 ↗
56. Functional gradient metallic prototypes through shape deposition manufacturing
57. Additive manufacturing of Inconel 718 — Copper alloy bimetallic structure using laser engineered net shaping (LENS™)
58. Composition control in the direct laser-deposition process10.1007/s11663-003-0070-5 ↗
59. Fabrication of x-graded H13 and Cu powder mix using high power pulsed Nd:YAG laser
60. Laser melting functionally graded composition of Waspaloy and Zirconia powders10.1007/s10853-007-1661-3 ↗
61. Functional gradient material of Ti-6Al-4V and γ-TiAl fabricated by electron beam selective melting