The scientists designed the actual nonlinear gradient pathway by coupling state-of-the-art computational thermodynamics with experimental data gathered via multiscale, high-throughput characterization tools. By doing so, they successfully circumvented welding issues and joined normally nonweldable superalloys with refractory alloys. The team analyzed the stress states of these integrated builds with neutron diffraction-based studies at ORNL, validating the computational alloy design. Currently, melt pool, thermal, and strain models are being generated based on the experimental data.
“Few additive manufacturing modalities have this capability of mixing powders on the go during the build,” Nag says. “This is a unique attribute that can blow powders at different rates. Now you can do temperature transition from a relatively low-temperature nickel alloy to an extremely high-temperature niobium alloy without any problem.”
An electron microscopy image shows the entire gradient transition from In718 to C103 and high magnification highlighting defect-free compositional transition. Credit: Tracie Lowe, Andres Marquez Rossy/ORNL, U.S. Department of Energy
First published July 21, 2023, in ORNL News.
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“We can enable compositions that transition from one alloy to another seamlessly,” says Soumya Nag, an ORNL materials scientist who is leading the studies. “We can tune a composite part that we can grade from one end to another and have high-strength and high-temperature capability on each side.”
(Oak Ridge National Laboratory: Oak Ridge, TN) — Research into a unique technology to fabricate composite metal parts for a wide range of applications operating in extreme environments across the aviation, space, and energy industries is showing promise for additive manufacturing.
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Shown are additively manufactured, thin-walled, functionally graded builds from IN718 to C103 alloys via a thick transition layer having high specific strength. Credit: Brian Jordan, Soumya Nag, ORNL/U.S. Department of Energy
In the latest studies, the scientists used powders of Inconel 718, a nickel-based alloy, and C103, a niobium-based alloy. These alloys—one high-strength and the other high-temperature resistant—do not want to join and tend to create cracks when they do. But by using a blown-powder, directed-energy deposition beam machine and changing the rate at which the powders flow, the scientists can change the composition of the joined metals so that the composition has the beneficial properties of both.
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منبع: https://www.qualitydigest.com/inside/innovation-news/secret-sauce-enables-new-way-fabricate-compositionally-graded-alloys-080823