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: Metal Additive ManufacturingSelective Laser Melting – Custom AlloysArc-Welding – Larger Structures
Consortium for Innovation in Materials and Manufacturing
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SST2: Metal Additive Manufacturing
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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
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Alloy Making and Qualification
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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
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Spinning Electrode Melt SimulationsPowder Size Distribution Prediction
Metal Powder Synthesis for Additive Manufacturing
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316 Stainless Steel
TiAl6V4
Shengming Guo’s & D. E. Nikitopoulos’ Groups
Alloy Stock
Powder BatchPowder Composition and Size Characterization
Metal Powder Synthesis
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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
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Electrostatic Levitation (ESL) forMetal/Alloy Melt Property Measurement
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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
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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
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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
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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
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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