Laser powder bed fusion (LPBF) is an innovative method where metal powder is fused together to generate complex geometries. LPBF is used as a technology to reduce material waste, and extensive labor that are often linked to conventional subtractive manufacturing. H13 tool steel is one of the widely used materials...
Selective laser melting (SLM) is an additive manufacturing (AM) process that uses a laser beam to melt metal powder as it is spread onto the build surface using a roller or scraper, followed by rapid solidification to manufacture a 3D component, one layer at a time.
In SLM process, density...
High Entropy Alloys (HEA) exhibit unusual properties and are gaining interest as new materials for challenging applications in the aerospace, hypersonic and medical fields. The application of HEAs have been limited by the development of powder production at scale. A recently developed process of plasma spheroidization by 6K, inc. has...
Having a series of excellent properties, the oxide dispersion-strengthened (ODS) steels provide promising solutions for the challenges of structural materials in nuclear energy, especially the development of future advanced nuclear fission and even fusion reactors. The current manufacturing route for ODS alloys includes mechanical alloying (MA) of master alloys or...
This study investigates the microstructure and mechanical properties of an austenitic Oxide Dispersion Strengthened (ODS) steel produced by the Laser Directed Energy Deposition (LDED) process using powder feedstock atomized with elemental yttrium. The Microstructure of the samples was characterized by electron microscopy, and mechanical properties were measured using a tensile...
A nickel-based Hastelloy C22 powder with a nominal composition of Ni-21.30Cr-13.36Mo-1.92Co-2.94W-3.85Fe-0.23Mn-0.3V(wt%) and particle size distribution of D₁₀=23.8±0.3 μm, D₅₀=37.5±0.2μm, and D₉₀=59.3±1.1 μm was gas atomized to be used as a feedstock in Laser Powder Bed Fusion (LPBF). In this study, laser power and scanning speed were optimized to manufacture specimens...
The current knowledge on the microstructural evolutions and mechanical properties of selective laser melting (SLM) produced H13 tool steel components is limited. This research is focused on optimization of SLM processing parameters for H13 tool steel and investigation of microstructure and mechanical properties of H13 tool steel components after SLM...
The aim of this work was to assess the viability of duplex stainless steel 2205 components built via selective laser melting for seawater applications. First, a comprehensive additive manufacturing assessment was done. The duplex stainless steel 2205 components were selectively laser melted from gas atomized powder (D90 <45m) using a...
The recyclability of 316L stainless steel powder in the binder jetting process has been determined. The powder characterization results demonstrated a 22% increase in the number of coarse particles (> 30 µm) and an 18.2% reduction in the number of small particles (< 10 µm) after recycling up to 16 times. A...
Gas-atomized Fe–24Cr–8Al–0.5Y (wt.%) powder was used as a feedstock in a laser powder bed fusion process with nitrogen atmosphere. Formation of Al–Y–O-enriched nanoparticles with diameters of 10–100 nm implied in-situ precipitation of Al–Y–O-enriched nanoparticles within the ferritic matrix developing an oxide dispersion strengthened FeCrAl alloy without any mechanical alloying. Thermodynamics...
Water-atomized and gas-atomized 17-4 PH stainless steel powder were used as feedstock in selective laser melting process. Gas atomized powder revealed single martensitic phase after printing and heat treatment independent of energy density. As-printed water atomized powder contained dual martensitic and austenitic phase regardless of energy density. The H900 heat...
H13 components with a relative density of ∼99% were additively manufactured using the selective laser melting (SLM) process. The highest density part (relevant density 99%) with the lowest level of porosity (<0.01%) was made with a volumetric energy density of 760 J/mm3 (152 W laser power, 100 mm/s scanning speed,...
Directed energy deposition and laser cladding technologies are suitable advanced manufacturing techniques for applying corrosion-resistant claddings to large carbon steel components. In this work, we clad 309L stainless steel wire onto carbon steel substrates and examine the effects of cladding parameters (laser power and travel speed) on metallurgical bonding, composition,...
Powder Metallurgy Hot Isostatic Pressing (PM-HIP) is a widely recognized powder metallurgy manufacturing process to produce near-net-shape and net-shape components. During general PM-HIP processes the metal powders are filled within a capsule (die), heated and loaded with high pressure simultaneously, and solidified to form the final product. Due to the...
The ultimate goal of this work is to analyze and compare two predictive models of thermal profile in laser processing of materials. An analytical method that uses closed-form equations to represent a geometric model of a laser heat source will be contrasted with a commercial computational fluid dynamics code that...
Soft robotics utilizes compliant materials (such as rubber) to make robots that are flexible and safe around humans, however these materials present many practical manufacturing challenges. Current fabrication methods use molding techniques which limits the soft robot designs which could be fabricated and impacts part consistency. This defense introduces a...
Manufacturing exists as a stronghold for continuous growth and development of economies, a trend that is likely to continue as the demand for commodities and products grow. Manufacturing drives innovation and productivity in developed nations, as well as promoting economic stability and development in developing nations. However, manufacturing activities pose...
This paper discusses the fundamentals of a novel hybrid method to synthesize oxide dispersion strengthened (ODS) 304 L stainless steel (SS) alloy using a modified laser powder bed fusion (LPBF) machine. Previously, ODS metal matrix composites have been produced by LPBF via ball-milling, which is expensive to scale. Here, we selectively...
Oxide dispersion strengthened (ODS) alloys exhibit superior mechanical properties due to the presence of nano-sized thermally stable oxide particles. However, manufacturing of ODS alloys is very complex and composed of numerous time consuming steps such as mechanical alloying, which is one of the main barriers toward the widespread application of...
The role of volumetric energy density on the microstructural evolution, texture and mechanical properties of 304L stainless steel parts additively manufactured via selective laser melting process is investigated. 304L is chosen because it is a potential candidate to be used as a matrix in a metal matrix composite with nanoparticles...
Low carbon steels (LCS) due to their high strength-to-cost ratio are one of the most ubiquitous materials used for a wide range of applications, including but not limited to automotive, construction, and transportation. However, the low corrosion resistance of LCS in neutral, acidic, or saline environments limits its utilization and...
Metallic glasses (MGs), also called amorphous metals, are metals or metallic alloys trapped in a disordered glassy state. Their amorphous nature and absence of features such as crystal lattices and defects (dislocations, grain boundaries etc.) endows them with a host of properties that far surpass those of common crystalline materials....
Laser Powder Bed Fusion (LPBF) is a process commonly used to create additively manufactured metal parts. The flexibility and complexity allowed by the LPBF process provides opportunity for significant advancement in multiple industries as parts can be customized in shape and function for specific needs. These benefits can be compounded...
Advances in plant construction within the energy and chemical process industries require inexpensive process intensification (PI) technology as a means to reduce plant size for enabling modular construction. One form of PI is microchannel process technology where arrays of microchannels, having hydraulic diameters on the order of 0.1 to 1...
With the increased demand for high-quality products, reliable and robust process monitoring has become a key capability for modern manufacturing systems. Through sensors installed in the machinery, the real-time information was measured to assess the state of the processes. The measured data can be used to infer the mechanical, material,...
In the second chapter, a foam-core meniscus coating process was developed for retrofitting 100 nm-scale sol-gel anti-reflective coatings onto in-field solar panels through the deposition, evaporation, and curing of wet films.Advantages of this technique include the means to control fluid flow relative to substrate motion and the ability to conform...
Sensing is a significant engineering science which quantify parameters from the physical world and discover the physics running behind the measurement process. Optical sensing makes use of electromagnetic waves from infrared to ultraviolet on the light spectrum as a medium to measure variables, such as position, temperature and strain. Image...