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- Mechanical and Aerospace Engineering Faculty Research & Creative Works (5)
- Department of Mechanical and Materials Engineering: Faculty Publications (3)
- Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research (1)
- Materials Science and Engineering Faculty Research & Creative Works (1)
- Research outputs 2022 to 2026 (1)
Articles 1 - 12 of 12
Full-Text Articles in Engineering
Advances In Additively Manufactured Titanium Alloys By Powder Bed Fusion And Directed Energy Deposition: Microstructure, Defects, And Mechanical Behavior, Hongyi Y. Ma, J. C. Wang, Peng Qin, Y. J. Liu, L. Y. Chen, L. Q. Wang, Laichang Zhang
Advances In Additively Manufactured Titanium Alloys By Powder Bed Fusion And Directed Energy Deposition: Microstructure, Defects, And Mechanical Behavior, Hongyi Y. Ma, J. C. Wang, Peng Qin, Y. J. Liu, L. Y. Chen, L. Q. Wang, Laichang Zhang
Research outputs 2022 to 2026
Ti and its alloys have been broadly adopted across various industries owing to their outstanding properties, such as high strength-to-weight ratio, excellent fatigue performance, exceptional corrosion resistance and so on. Additive manufacturing (AM) is a complement to, rather than a replacement for, traditional manufacturing processes. It enhances flexibility in fabricating complex components and resolves machining challenges, resulting in reduced lead times for custom designs. However, owing to distinctions among various AM technologies, Ti alloys fabricated by different AM methods usually present differences in microstructure and defects, which can significantly influence the mechanical performance of built parts. Therefore, having an in-depth …
Heat Treatments For Minimization Of Residual Stresses And Maximization Of Tensile Strengths Of Scalmalloy® Processed Via Directed Energy Deposition, Rachel Boillat-Newport, Sriram Praneeth Isanaka, Jonathan Kelley, Frank Liou
Heat Treatments For Minimization Of Residual Stresses And Maximization Of Tensile Strengths Of Scalmalloy® Processed Via Directed Energy Deposition, Rachel Boillat-Newport, Sriram Praneeth Isanaka, Jonathan Kelley, Frank Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Scalmalloy® is an Al-Mg-Sc-Zr-Based Alloy Specifically Developed for Additive Manufacturing (AM). This Alloy is Designed for Use with a Direct Aging Treatment, as Recommended by the Manufacturer, Rather Than with a Multistep Treatment, as Often Seen in Conventional Manufacturing. Most Work with Scalmalloy® is Conducted using Powder Bed Rather Than Powder-Fed Processes. This Investigation Seeks to Fill This Knowledge Gap and Expand Beyond Single-Step Aging to Promote an overall Balanced AM-Fabricated Component. for This Study, Directed Energy Deposition (DED)-Fabricated Scalmalloy® Components Were Subjected to Low-Temperature Treatments to Minimize Residual Stresses Inherent in the Material Due to the Layer-By-Layer Build Process. …
Increased Ductility Of Ti-6al-4v By Interlayer Milling During Directed Energy Deposition, Rakeshkumar Karunakaran, Luz D. Sotelo, Hitarth Maharaja, Calsey Nez, Monsuru Ramoni, Scott Halliday, Sushil Mishra, Joseph A. Turner, Michael P. Sealy
Increased Ductility Of Ti-6al-4v By Interlayer Milling During Directed Energy Deposition, Rakeshkumar Karunakaran, Luz D. Sotelo, Hitarth Maharaja, Calsey Nez, Monsuru Ramoni, Scott Halliday, Sushil Mishra, Joseph A. Turner, Michael P. Sealy
Department of Mechanical and Materials Engineering: Faculty Publications
Additive manufacturing (AM) often results in high strength but poor ductility in titanium alloys. Hybrid AM is a solution capable of improving both ductility and strength. In this study, hybrid AM of Ti-6Al-4V was achieved by coupling directed energy deposition with interlayer machining. The microstructure, residual stress, and microhardness were examined to explain how interlayer machining caused a 63% improvement in ductility while retaining an equivalent strength to as-printed samples. Interlayer machining introduced recurrent interruptions in printing that allowed for slow cooling-induced coarsening of acicular α laths at the machined interfaces. The coarse α laths on the selectively machined layers …
Tini-Based Bi-Metallic Shape-Memory Alloy By Laser-Directed Energy Deposition, Yitao Chen, Cesar Ortiz Rios, Braden Mclain, Joseph William Newkirk, Frank W. Liou
Tini-Based Bi-Metallic Shape-Memory Alloy By Laser-Directed Energy Deposition, Yitao Chen, Cesar Ortiz Rios, Braden Mclain, Joseph William Newkirk, Frank W. Liou
Materials Science and Engineering Faculty Research & Creative Works
In this study, laser-directed energy deposition was applied to build a Ti-rich ternary Ti–Ni–Cu shape-memory alloy onto a TiNi shape-memory alloy substrate to realize the joining of the multifunctional bi-metallic shape-memory alloy structure. The cost-effective Ti, Ni, and Cu elemental powder blend was used for raw materials. Various material characterization approaches were applied to reveal different material properties in two sections. The as-fabricated Ti–Ni–Cu alloy microstructure has the TiNi phase as the matrix with Ti2Ni secondary precipitates. The hardness shows no high values indicating that the major phase is not hard intermetallic. A bonding strength of 569.1 MPa was obtained …
Closed-Loop Control Of Meltpool Temperature In Directed Energy Deposition, Ziyad M. Smoqi, Ben Bevans, Aniruddha Gaikwad, James Craig, Alan Abul-Haj, Brent Roeder, Bill Macy, Jeffrey E. Shield, Prahalada K. Rao
Closed-Loop Control Of Meltpool Temperature In Directed Energy Deposition, Ziyad M. Smoqi, Ben Bevans, Aniruddha Gaikwad, James Craig, Alan Abul-Haj, Brent Roeder, Bill Macy, Jeffrey E. Shield, Prahalada K. Rao
Department of Mechanical and Materials Engineering: Faculty Publications
The objective of this work is to mitigate flaw formation in powder and laser-based directed energy deposition (DED) additive manufacturing process through close-loop control of the meltpool temperature. In this work, the meltpool temperature was controlled by modulating the laser power based on feedback signals from a coaxial two-wavelength imaging pyrometer. The utility of closed-loop control in DED is demonstrated in the context of practically inspired trapezoid-shaped stainlesssteel parts (SS 316L). We demonstrate that parts built under closed-loop control have reduced variation in porosity and uniform microstructure compared to parts built under open-loop conditions. For example, post-process characterization showed that …
Additive Manufacturing Of Stainless Steel -- Copper Functionally Graded Materials Via Inconel 718 Interlayer, Xinchang Zhang, Lan Li, Frank W. Liou
Additive Manufacturing Of Stainless Steel -- Copper Functionally Graded Materials Via Inconel 718 Interlayer, Xinchang Zhang, Lan Li, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The joining of dissimilar materials is becoming increasingly prevalent to integrate different material properties to enhance design flexibility and overall performance. This study introduced an innovative approach to additively manufacture copper on 316L stainless steel (SS316L) via Inconel 718 interlayers using directed energy deposition (DED). The novel multi-material structure was studied both experimentally and theoretically. The microstructure, tensile properties, microhardness, and thermal performance of the structure were characterized. Residual stress distribution over the structure was revealed by experimental-validated numerical modeling. The result exhibits that defect-free structures with excellent interfacial bonding can be achieved by introducing Inconel 718 interlayers. The bonding …
The Effect Of Nanostructures In Aluminum Alloys Processed Using Additive Manufacturing On Microstructural Evolution And Mechanical Performance Behavior, Rachel Boillat, Sriram Praneeth Isanaka, Frank W. Liou
The Effect Of Nanostructures In Aluminum Alloys Processed Using Additive Manufacturing On Microstructural Evolution And Mechanical Performance Behavior, Rachel Boillat, Sriram Praneeth Isanaka, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
This paper reviews the status of nanoparticle technology as it relates to the additive manufacturing (AM) of aluminum-based alloys. A broad overview of common AM processes is given. Additive manufacturing is a promising field for the advancement of manufacturing due to its ability to yield near-net-shaped components that require minimal post-processing prior to end-use. AM also allows for the fabrication of prototypes as well as economical small batch production. Aluminum alloys processed via AM would be very beneficial to the manufacturing industry due to their high strength to weight ratio; however, many of the conventional alloy compositions have been shown …
Experimental And Numerical Investigation In Directed Energy Deposition For Component Repair, Lan Li, Xinchang Zhang, Frank W. Liou
Experimental And Numerical Investigation In Directed Energy Deposition For Component Repair, Lan Li, Xinchang Zhang, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
Directed energy deposition (DED) has been widely used for component repair. In the repair process, the surface defects are machined to a groove or slot and then refilled. The sidewall inclination angle of the groove geometry has been recognized to have a considerable impact on the mechanical properties of repaired parts. The objective of this work was to investigate the feasibility of repairing various V-shaped defects with both experiments and modeling. At first, the repair volume was defined by scanning the defective zone. Then, the repair volume was sliced to generate the repair toolpath. After that, the DED process was …
Process-Structure Relationship In The Directed Energy Deposition Of Cobalt-Chromium Alloy (Stellite 21) Coatings, Ziyad M. Smoqi, Joshua Toddy, Harold (Scott) Halliday, Jeffrey E. Shield, Prahalada K. Rao
Process-Structure Relationship In The Directed Energy Deposition Of Cobalt-Chromium Alloy (Stellite 21) Coatings, Ziyad M. Smoqi, Joshua Toddy, Harold (Scott) Halliday, Jeffrey E. Shield, Prahalada K. Rao
Department of Mechanical and Materials Engineering: Faculty Publications
In this work, we accomplished the crack-free directed energy deposition (DED) of a multi-layer Cobalt- Chromium alloy coating (Stellite 21) on Inconel 718 substrate. Stellite alloys are used as coating materials given their resistance to wear, corrosion, and high temperature. The main challenge in DED of Stellite coatings is the proclivity for crack formation during printing. The objective of this work is to characterize the effect of the input energy density and localized laser-based preheating on the characteristics of the deposited coating, namely, crack formation, microstructural evolution, dilution of the coating composition due to diffusion of iron and nickel from …
A Review On Metallic Alloys Fabrication Using Elemental Powder Blends By Laser Powder Directed Energy Deposition Process, Yitao Chen, Xinchang Zhang, Mohammad Masud Parvez, Frank W. Liou
A Review On Metallic Alloys Fabrication Using Elemental Powder Blends By Laser Powder Directed Energy Deposition Process, Yitao Chen, Xinchang Zhang, Mohammad Masud Parvez, Frank W. Liou
Mechanical and Aerospace Engineering Faculty Research & Creative Works
The laser powder directed energy deposition process is a metal additive manufacturing technique, which can fabricate metal parts with high geometric and material flexibility. The unique feature of in-situ powder feeding makes it possible to customize the elemental composition using elemental powder mixture during the fabrication process. Thus, it can be potentially applied to synthesize industrial alloys with low cost, modify alloys with different powder mixtures, and design novel alloys with location-dependent properties using elemental powder blends as feedstocks. This paper provides an overview of using a laser powder directed energy deposition method to fabricate various types of alloys by …
Additive Manufacturing Of Ti6al4v Alloy: A Review, Shunyu Liu, Yung C. Shin
Additive Manufacturing Of Ti6al4v Alloy: A Review, Shunyu Liu, Yung C. Shin
School of Mechanical Engineering Faculty Publications
In this paper, the recent progress on Ti6Al4V fabricated by three mostly developed additive manufacturing (AM) techniques-directed energy deposition (DED), selective laser melting (SLM) and electron beammelting (EBM)-is thoroughly investigated and compared. Fundamental knowledge is provided for the creation of links between processing parameters, resultant microstructures and associated mechanical properties. Room temperature tensile and fatigue properties are also reviewed and compared to traditionally manufactured Ti6Al4V parts. The presence of defects in as-builtAMTi6Al4V components and the influences of these defects on mechanical performances are also critically discussed.
Modeling Residual Stress Development In Hybrid Processing By Additive Manufacturing And Laser Shock Peening, Guru Charan Reddy Madireddy
Modeling Residual Stress Development In Hybrid Processing By Additive Manufacturing And Laser Shock Peening, Guru Charan Reddy Madireddy
Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research
The term “hybrid” has been widely applied to many areas of manufacturing. Naturally, that term has found a home in additive manufacturing as well. Hybrid additive manufacturing or hybrid-AM has been used to describe multi-material printing, combined machines (e.g., deposition printing and milling machine center), and combined processes (e.g., printing and interlayer laser re-melting). The capabilities afforded by hybrid-AM are rewriting the design rules for materials and adding a new dimension in the design for additive manufacturing paradigm. This work focuses on hybrid-AM processes, which are defined as the use of additive manufacturing (AM) with one …