On the Mechanical Behavior of LP-DED C103 Thin-Wall Structures
Abstract
:1. Introduction
Element | Nb | Hf | Ti | Zr | W | Ta |
---|---|---|---|---|---|---|
% | Bal. | 9.0–11.0 | 0.7–1.3 | <0.7 | <0.5 | <0.5 |
2. Materials and Methods
2.1. Surface Topography
2.2. Heat Treatment
2.3. Tensile Testing
2.4. Fatigue Testing
3. Results and Discussion
3.1. Surface Topography
3.2. Tensile Testing
3.3. Tensile Fractography
3.4. Fatigue Testing
3.5. Fatigue Fractography
4. Summary and Conclusions
- Subtracting the maximum peak height (Rp) twice from the caliper measured thickness provided the most accurate estimate of the load bearing area. The use of caliper-based measurements tends to underestimate the material properties. Additional work is required to characterize this approach for specimens printed at an angle with different surface roughness values for the upskin and downskin of the material.
- Mechanical properties of LP-DED C103 are greater than their wrought counterparts. The large grain size resulting from LP-DED led to properties below the reported EB-PBF and L-PBF values. Stress relief (SR) heat treatment schedule reduced both strength and ductility. Hot isostatic pressing (HIP) increased all properties above the as-built (AB) condition. This is a unique behavior to LP-DED C103 since HIP cycles are detrimental to L-PBF C103 due to induced grain growth. Additional exploratory work is required to develop heat treatment schedules that produce optimal mechanical properties.
- Fractography of the tensile specimens revealed mixed mode fracture composed of equiaxed dimples, highly elongated dimples, shear fracture, and transgranular fracture for all heat treatment–build orientation combinations. The dominant fracture mechanisms are thought to be unique for each build orientation studied in this work. Scanning electron microscope (SEM) images confirmed that the interlayers act as stress concentration sites for crack initiation when specimens are oriented vertical to the build direction. When the specimens are oriented horizontal to the build direction, the fracture appears to mainly propagate along the (01) plane.
- Fatigue results showed max life cycles ranging from 100 cycles to over 8000 cycles for 2% and 0.5% max strain level respectively. At the lowest max strain level, the samples did not reach runout target of 50,000 cycles. Additional testing is needed to evaluate the material’s response to high cycle fatigue (HCF) and establish a predictive life cycle model.
- Fractography of the fatigue specimens revealed consistent crack initiation sites along the edges of the samples within the interlayers. The cracks propagated across several deposited layers prior to the final fracture. As strain levels are increased, the crack propagation zone is increased. At the 0.5% max strain level, the specimen spends most of the test time under crack initiation and damage accumulation. At increased strain levels, crack propagation dominates for the majority of the time.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Laser Power | Deposition Speed | Flow Rate | Laser Spot Size |
---|---|---|---|
1420 W | 12.7 mm/min | 14.5 g/min | 1.4 mm |
Ra [m] | Rp [m] | Rv [m] | Rz [m] | Sa [m] | Sp [m] | Sv [m] | Sz [m] |
---|---|---|---|---|---|---|---|
17.92 ± 1.65 | 67.11 ± 3.55 | 47.77 ± 2.34 | 114.88 ± 1.65 | 14.66 ± 1.15 | 110.33 ± 8.73 | 58.00 ± 6.24 | 168.66 ± 10.21 |
Measurement Technique | Area [mm2] | %Diff from Optical |
---|---|---|
Optical | 4.926 ± 0.105 | — |
Calipers | 5.241 ± 0.039 | 6.37% |
Ra | 5.150 ± 0.041 | 4.53% |
Rp | 4.900 ± 0.056 | 0.54% |
Rv | 4.998 ± 0.047 | 1.45% |
Rz | 4.657 ± 0.065 | 5.46% |
Sa | 5.166 ± 0.033 | 4.86% |
Sp | 4.680 ± 0.006 | 4.99% |
Sv | 4.946 ± 0.049 | 0.39% |
Sz | 4.384 ± 0.028 | 11.01% |
Vertical Orientation | Horizontal Orientation | |||||
---|---|---|---|---|---|---|
Heat Treatment | YS [MPa] | UTS [MPa] | %E | YS [MPa] | UTS [MPa] | %E |
AB | 285.46 ± 6.50 | 370.92 ± 5.10 | 33.68 ± 1.86 | 316.56 ± 8.96 | 395.02 ± 1.75 | 32.80 ± 4.75 |
SR | 241.85 ± 4.08 | 366.29 ± 4.47 | 35.82 ± 1.28 | 285.00 ± 3.95 | 378.84 ± 3.11 | 32.67 ± 3.39 |
HIP | 296.23 ± 8.37 | 400.61 ± 2.03 | 44.48 ± 3.91 | 321.32 * | 418.07 * | 34.50 * |
Wrought [9] | 283 | 411 | 41 | – | – | – |
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Colón, B.; Pourjam, M.; Demeneghi, G.; Hazeli, K.; Mireles, O.; Medina, F. On the Mechanical Behavior of LP-DED C103 Thin-Wall Structures. Metals 2024, 14, 958. https://doi.org/10.3390/met14090958
Colón B, Pourjam M, Demeneghi G, Hazeli K, Mireles O, Medina F. On the Mechanical Behavior of LP-DED C103 Thin-Wall Structures. Metals. 2024; 14(9):958. https://doi.org/10.3390/met14090958
Chicago/Turabian StyleColón, Brandon, Mehrdad Pourjam, Gabriel Demeneghi, Kavan Hazeli, Omar Mireles, and Francisco Medina. 2024. "On the Mechanical Behavior of LP-DED C103 Thin-Wall Structures" Metals 14, no. 9: 958. https://doi.org/10.3390/met14090958