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Register a new userVibratory Powder Feeding for Powder Bed AdditiveManufacturing using Water and Gas Atomized MetalPowders
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Commercial powder bed fusion additive manufacturing systems use recoaters for the layer-by-layer distribution of powder. Despite the known limitations of recoaters, there has been relatively little work presented on the possible benefits of alternative powder delivery systems. Here, we show the use of a technology using simple vibration to control the powder flow for powder bed additive manufacturing. The capabilities of this approach are illustrated experimentally using two very different powders; a `conventional gas atomized Ti-6Al-4V powder designed for electron beam additive manufacturing and a water atomized Fe-4wt%Ni alloy used in powder metallurgy. Discrete element modelling is used to reveal the mechanisms controlling the dependence of feed rate on feeder process parameters and to investigate the potential strengths and limitations of this approach.
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Powder-based additive manufacturing techniques provide tools to construct intricate structures that are difficult to manufacture using conventional methods. In Laser Powder Bed Fusion, components are built by selectively melting specific areas of the powder bed, to form the two-dimensional cross-section of the specific part. However, the high occurrence of defects impacts the adoption of this method for precision applications. Therefore, a control policy for dynamically altering process parameters to avoid phenomena that lead to defect occurrences is necessary. A Deep Reinforcement Learning (DRL) framework that derives a versatile control strategy for minimizing the likelihood of these defects is presented. The generated control policy alters the velocity of the laser during the melting process to ensure the consistency of the melt pool and reduce overheating in the generated product. The control policy is trained and validated on efficient simulations of the continuum temperature distribution of the powder bed layer under various laser trajectories.
Quality control in additive manufacturing can be achieved through variation control of the quantity of interest (QoI). We choose in this work the microstructural microsegregation to be our QoI. Microsegregation results from the spatial redistribution of a solute element across the solid-liquid interface that forms during solidification of an alloy melt pool during the laser powder bed fusion process. Since the process as well as the alloy parameters contribute to the statistical variation in microstructural features, uncertainty analysis of the QoI is essential. High-throughput phase-field simulations estimate the solid-liquid interfaces that grow for the melt pool solidification conditions that were estimated from finite element simulations. Microsegregation was determined from the simulated interfaces for different process and alloy parameters. Correlation, regression, and surrogate model analyses were used to quantify the contribution of different sources of uncertainty to the QoI variability. We found negligible contributions of thermal gradient and Gibbs-Thomson coefficient and considerable contributions of solidification velocity, liquid diffusivity, and segregation coefficient on the QoI. Cumulative distribution functions and probability density functions were used to analyze the distribution of the QoI during solidification. Our approach, for the first time, identifies the uncertainty sources and frequency densities of the QoI in the solidification regime relevant to additive manufacturing.
Information on the lattice parameter of single crystals with known crystallographic structure allows for estimations of sample quality and composition. In many cases it is suffcient to determine one lattice parameter or the lattice spacing along a certain, high-symmetry direction, e.g. in order to determine the composition in a substitution series by taking advantage of Vegards rule. Here we present a guide to accurate measurements of single crystals with dimensions ranging from 200 $mu$m up to several millimeter using a standard powder diffractometer in Bragg-Brentano geometry. The correction of the error introduced by the sample height and the optimization of the alignment are discussed in detail. In particular for single crystals with a plate-like habit, the described procedure allows for measurement of the lattice spacings normal to the plates with high accuracy on a timescale of minutes.
We report dc transport and magnetization measurements of Jc in MgB2 wires fabricated by the powder-in-tube method, using commercial MgB2 powder with 5 %at Mg powder added as an additional source of magnesium, and stainless steel as sheath material. By appropriate heat treatments, we have been able to increase Jc by more than one order of magnitude from that of the as-drawn wire. We show that one beneficial effect of the annealing is the elimination of most of the micro-cracks, and we correlate the increase in Jc with the disappearance of the weak-link-type behavior.
The crystallization and magnetic behavior of yttrium iron garnet (YIG) prepared by metallo-organic decomposition (MOD) method are discussed. The chemistry and physics related to synthesis of iron and yttrium carboxylates based on 2-ethylhexanoic acid (2EHA) are studied, since no literature was found which elucidates synthesis of metallo-organic precursor of YIG in spite of the literatures of doped YIG samples such as Bi-YIG. Typically, the metal carboxylates used in preparation of ceramic oxide materials are 2-ethylhexanoate (2EH) solvents. Herein, the synthesis, thermal behavior and solubility of yttrium and iron 2EH used in synthesis of YIG powder by MOD are reported. The crystallization and magnetic parameters, including saturation magnetization and coercivity of these samples, smoothly change as a function of the annealing temperature. It is observed that high sintering temperature of 1300 to 1400 {deg}C promotes the diffraction peaks of YIG, therefore, we can conclude that the formation of YIG in MOD method increases the crystallization temperature. The maximum value of saturation magnetization and minimum value of coercivity and remanence are observed for the sample sintered at 1200{deg}C which are 13.7 emu/g, 10.38 Oe and 1.5 emu/g, respectively. This study cites the drawbacks in chemical synthesis of metallo-organic based YIG production.
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