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Register a new userUltra strong and ductile eutectic high entropy alloy fabricated by selective laser melting
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With important application prospects, eutectic high entropy alloys have received extensive attention for their excellent strength and ductility in a large temperature range. The excellent casting characteristics of eutectic high entropy alloys make it possible to achieve well manufacturability of selective laser melting. For the first time, we have achieved crack-free eutectic high entropy alloy fabricated by selective laser melting, which has excellent mechanical properties in a wide temperature range of -196 degrees Celsius~760 degrees Celsius due to ultra-fine eutectic lamellar spacing of 150 ~ 200nm and lamellar colony of 2 ~ 6 {mu}m. Specifically, the room temperature tensile strength exceeds 1400MPa and the elongation is more than 20%, significantly improved compared with those manufactured by other techniques with lower cooling rate.
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Selective laser melting (SLM) is rapidly evolving to become a mainstream technology. However, the fundamental mechanisms of solidification and microstructure development inherent to the non-equilibrium conditions of this additive manufacturing method, which differ largely from those typical of conventional processing techniques, remain widely unknown. In this work, an in-depth characterization of the microstructure of Al7075 SLM processed samples, built from powder mixtures containing ZrH2 microparticles, demonstrates the occurrence of icosahedral quasicrystal-enhanced nucleation during laser fabrication. This solidification mechanism, only observed to date in cast Al-Zn and yellow gold alloys containing minute additions of Cr (Kurtuldu et al., 2013) or Ti (Chen et al. 2018), and Ir (Kurtuldu et al., 2014), is evidenced by the presence of an abnormally high fraction of twin boundaries and of five-fold orientation symmetry between twinned nearest neighbors lying within a matrix of equiaxed, randomly textured, ultrafine grains. This research attests to the wide range of possibilities offered by additive manufacturing methods for the investigation of novel physical metallurgy phenomena as well as for the design of advanced metals.
This article presents a new and individual way to generate opto-mechanical components by Additive Manufacturing, embedded in an established process chain for the fabrication of metal optics. The freedom of design offered by additive techniques gives the opportunity to produce more lightweight parts with improved mechanical stability. The latter is demonstrated by simulations of several models of metal mirrors with a constant outer shape but varying mass reduction factors. The optimized lightweight mirror exhibits $63.5 %$ of mass reduction and a higher stiffness compared to conventional designs, but it is not manufacturable by cutting techniques. Utilizing Selective Laser Melting instead, a demonstrator of the mentioned topological non-trivial design is manufactured out of AlSi12 alloy powder. It is further shown that -- like in case of a traditional manufactured mirror substrate -- optical quality can be achieved by diamond turning, electroless nickel plating, and polishing techniques, which finally results in $< 150$~nm peak-to-valley shape deviation and a roughness of $< 1$~nm rms in a measurement area of $140 times 110$ $mu$m${}^2$. Negative implications from the additive manufacturing are shown to be negligible. Further it is shown that surface form is maintained over a two year storage period under ambient conditions.
In order to predict the more accurate shape information of the melt pool in Selective Laser Melting (SLM), a new finite element temperature field simulations model is proposed. The simulations use a new heat source model that takes into account the influence of the powder layout, the surface of the substrate and the changes in the thickness of the powder layer after fusion on the energy distribution. In order to construct this new heat source model, firstly an improved optimization method based on the gradient descent and the univariate search technique is proposed to simulate the powder layout, and then the laser beam propagation between the powder and the surface of the substrate is tracked and recorded to obtain the energy distribution. Finally, according to the distribution of laser energy between the powder layer and the surface of the substrate, the heat source model is divided into two parts: one is the surface of substrate heat source model being the Gaussian distribution, the other one is the powder layer heat source model-satisfying the Gaussian distribution on the horizontal plane, changes in the depth direction according to the functional relationship obtained by the fitting. In addition, the thickness change of the powder layer after fusion is analyzed, and is taken into account in the heat source model. The powder simulation results are compared with the powder scattering experiment results to verify the effectiveness of the powder model. Comparing the temperature field simulation with the experiment, the results show that the predicted molten pool width relative error is 6.4%, and the connect width error is 9.6%, which has better accuracy and verifies the validity of the temperature field simulation model.
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Increasing pressure on the power industry to reduce carbon emissions has led to increased research into the use of biomass feedstocks. This work investigates the effects of HCl and KCl, key species influencing biomass boiler corrosion, on a laser clad coating of the FeCrAl alloy Kanthal APMT. In-Situ SEM exposure of the coating at 450 oC for 1 h was performed to investigate the initial effects of KCl on the corrosion process. The same coatings were exposed to 250 h exposures in both an air environment and a HCl rich environment. The influence of KCl was investigated in both. Evidence of a slow growing aluminium oxide was observed. It was found that HCl allowed chlorine based corrosion to occur suggesting it can interact from the gas phase. It was also observed that the presence of both HCl and KCl reduced the mass gain compared to KCl in an air environment.
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