1

: Metal Additive ManufacturingSelective Laser Melting – Custom AlloysArc-Welding – Larger Structures

Consortium for Innovation in Materials and Manufacturing

SST2: Metal Additive Manufacturing

2

Example:High Entropy Alloys

(HEA)Custom

Alloys for SLM

STT2.3

SLM Process

STT2.4

Property Measurement & Characterization

STT2.1

Multi-scale Modeling

STT2.2

Powder Synthesis

5 or more elements in equal or near equal atomic percent

Alloy Making and Qualification

3

Site-Selective Indentation Tests:

Hardness, Modulus

CrMoNbReTaVWHigh Entropy Alloy (HEA)

EDS

EBSD

Groups: Guo, Meng, Sprunger (LSU); Yang (SU);Mainardi, Ramachandran (LATech); Derosa (GSU)

FIB

TEM

XRD

Composition Distribution

and Structure

AlloyMaking

Sample

ICME Approach

Simulations for Alloy Design (DFT, MD)

SIF

Equilibrium RapidSolidification:

Phase Diagram Calculations(CALPHAD)

HPC,

LoniElectronic Structure and Mechanical

& Thermo-Physical Properties

M2TF

Spinning Electrode Melt SimulationsPowder Size Distribution Prediction

Metal Powder Synthesis for Additive Manufacturing

4

316 Stainless Steel

TiAl6V4

Shengming Guo’s & D. E. Nikitopoulos’ Groups

Alloy Stock

Powder BatchPowder Composition and Size Characterization

Metal Powder Synthesis

SLM Process Studies for Alloy Powders

5Groups: Guo, Meng, Sprunger, Shao, Haber, Butler (LSU); Raush (ULL); Genov (LATech)

In-situ synchrotron XRD of SLM process

Alloy Phase Evolution

During SLM

HPC, Loni

Dislocation Dynamics MD

Simulation

Life-time Prediction

Laser-Material Interaction Experiment

1800 1850 1900 1950 2000 20501.00

1.25

1.50

1.75

2.00

2.25

Ti-6Al-4V

Ti-6Al-4V-10Mo

Wunderlich, Ti-64 (2005)

Schneider, Ti-64 (2002)

Egry, Ti-64 (g)

Egry, Ti-64 (2010)

Su

rfac

e T

ensi

on

(N

/m)

Temperature (K)

Tm

Surf. Tension1800 1900 2000 21002

4

6

8

10

12

Ti-6Al-4V

Ti-6Al-4V-10Mo

Ti-6Al-4V (Wunderlich 2005)

Vis

cosi

ty (

mP

a-s)

Temperature (K)

ESL Melt Property Measurement

Viscosity

Collaboration

NASA MSFC

SLM Process Simulation (ALE3D)

Collaboration

LLNL

Laser-Powder-Bed Interaction Simulation

Electrostatic Levitation (ESL) forMetal/Alloy Melt Property Measurement

6

ESL System

Faculty: Johnathan Raush (ULL), Wenjin Meng, Shengmin Guo, Phil Sprunger

M2TF

J. Raush working with NASA MSFC ESL team

In collaboration with NASA Marshall Space Flight Center

7

In-Situ SLM Process Diagnostics

In-situ study of high entropy alloy phase evolution under laser heating using synchrotron XRD

LSU

CAMD

Guo, Meng, Sprunger Groups

8

Diagnostics of SLM Process Outcomes

Butler, Khonsari and Guo Groups

Collaboration with NIST and Helmholtz Zentrum Berlin für Materialien und Energie (HZB)

Neutron Interferometry Detection of Early Crack Formation in Fatigued Additively

Manufactured SS316

9

SLM Process Sample Mechanical TestWith Neutron Scattering Diagnostics

Normalized dark-field in tomography on half-life sample runs has feature corresponding to location of eventual failure

Neutron Scattering Diagnostics Coupled To Mechanical Testing

Butler and Guo Groups

Materials Behavior & Structure

Integrated Multiscale Studies

10Shao and Meng Groups

Atomic/nano scale: DFT and MD

Microscale-experiments

Micro-compressionMicro-shear

Micro-tension

Informationpassing

Information passing

Micro scale: Dislocation DynamicsMeso scale: Visco-plastic self-

consistent (VPSC) model

An integrated multiscale experimentation and simulation approach to evaluate and predict mechanical properties of additive manufactured materials

Experiment

Multiscale Simulation Cascade