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1. Effect of Post Processing Heat Treatment Routes on Microstructure and Mechanical Property Evolution of Haynes 282 Ni-Based Superalloy Fabricated with Selective Laser Melting (SLM)

   https://doi.org/10.3390/met10050629  

   Deshpande, Anagh ; Deb Nath, Subrata ; Atre, Sundar ; Hsu, Keng ( May 2020 , Metals)

   Selective laser melting (SLM) is one of the most widely used additive manufacturing technologies. Fabricating nickel-based superalloys with SLM has garnered significant interest from the industry and the research community alike due to the excellent high temperature properties and thermal stability exhibited by the alloys. Haynes-282 alloy, a γ′-phase strengthened Ni-based superalloy, has shown good high temperature mechanical properties comparable to alloys like R-41, Waspaloy, and 263 alloy but with better fabricability. A study and comparison of the effect of different heat-treatment routes on microstructure and mechanical property evolution of Haynes-282 fabricated with SLM is lacking in the literature. Hence,more »in this manuscript, a thorough investigation of microstructure and mechanical properties after a three-step heat treatment and hot isostatic pressing (HIP) has been conducted. In-situ heat-treatment experiments were conducted in a transmission electron microscopy (TEM) to study γ′ precipitate evolution. γ′ precipitation was found to start at 950 °C during in-situ heat-treatment. Insights from the in-situ heat-treatment were used to decide the aging heat-treatment for the alloy. The three-step heat-treatment was found to increase yield strength (YS) and ultimate tensile strength (UTS). HIP process enabled γ′ precipitation and recrystallization of grains of the as-printed samples in one single step.« less
2. Additive Laser Metal Deposition Onto Silicon for Enhanced Microelectronics Cooling

   https://doi.org/10.1109/ECTC.2019.00302  

   Azizi, Arad ; Daeumer, Matthias A. ; Simmons, Jacob C. ; Sammakia, Bahgat G. ; Murray, Bruce T. ; Schiffres, Scott N. ( May 2019 , 2019 IEEE 69th Electronic Components and Technology Conference (ECTC))

   We previously demonstrated how the Sn3Ag4Ti alloy can robustly bond onto silicon via selective laser melting (SLM). By employing this technology, thermal management devices (e.g., micro-channels, vapor chamber evaporators, heat pipes) can be directly printed onto the electronic package (silicon die) without using thermal interface materials. Under immersion two-phase cooling (pool boiling), we compare the performance of three chip cooling methods (conventional heat sink, bare silicon die and additively manufactured metal micro-fins) under high heat flux conditions (100 W/cm2 ). Heat transfer simulations show a significant reduction in the chip temperature for the silicon micro-fins. Reduction of the chip operatingmore »temperature or increase in clock speed are some of the advantages of this technology, which results from the elimination of thermal interface materials in the electronic package. Performance and reliability aspects of this technology are discussed through experiments and computational models.« less
3. A defect-resistant Co–Ni superalloy for 3D printing

   https://doi.org/10.1038/s41467-020-18775-0  

   Murray, Sean P. ; Pusch, Kira M. ; Polonsky, Andrew T. ; Torbet, Chris J. ; Seward, Gareth G. E. ; Zhou, Ning ; Forsik, Stéphane A. J. ; Nandwana, Peeyush ; Kirka, Michael M. ; Dehoff, Ryan R. ; et al ( October 2020 , Nature Communications)

   Additive manufacturing promises a major transformation of the production of high economic value metallic materials, enabling innovative, geometrically complex designs with minimal material waste. The overarching challenge is to design alloys that are compatible with the unique additive processing conditions while maintaining material properties sufficient for the challenging environments encountered in energy, space, and nuclear applications. Here we describe a class of high strength, defect-resistant 3D printable superalloys containing approximately equal parts of Co and Ni along with Al, Cr, Ta and W that possess strengths in excess of 1.1 GPa in as-printed and post-processed forms and tensile ductilities ofmore »greater than 13% at room temperature. These alloys are amenable to crack-free 3D printing via electron beam melting (EBM) with preheat as well as selective laser melting (SLM) with limited preheat. Alloy design principles are described along with the structure and properties of EBM and SLM CoNi-base materials.

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4. Wear Performance Evaluation of Minimum Quantity Lubrication with Exfoliated Graphite Nanoplatelets in Turning Titanium Alloy

   Nguyen, D. ( May 2019 , Journal of manufacturing science and engineering)

   This paper evaluates the performances of dry, minimum quantity lubrication (MQL), and MQL with nanofluid conditions in turning of the most common titanium (Ti) alloy, Ti-6Al-4 V, in a solution treated and aged (STA) microstructure. In particular, the nanofluid evaluated here is vegetable (rapeseed) oil mixed with small concentrations of exfoliated graphite nanoplatelets (xGnPs). This paper focuses on turning process that imposes a challenging condition to apply the oil or nanofluid droplets directly onto the tribological surfaces of a cutting tool due to the uninterrupted engagement between tool and work material during cutting. A series of turning experiments was conductedmore »with uncoated carbide inserts, while measuring the cutting forces with a dynamometer under the dry, MQL and MQL with nanofluid conditions supplying oil droplets externally from our MQL device. The inserts are retrieved intermittently to measure the progress of flank and crater wear using a confocal microscopy. This preliminary experimental result shows that MQL and in particular MQL with the nanofluid significantly improve the machinability of Ti alloys even in turning process. However, to attain the best performance, the MQL conditions such as nozzle orientation and the concentration of xGnP must be optimized.« less
5. An Investigation Into the Challenges of Using Metal Additive Manufacturing for the Production of Patient-Specific Aneurysm Clips

   https://doi.org/10.1115/1.4043651  

   Walker, Brandon J. ; Cox, Benjamin L. ; Cikla, Ulas ; de Bellefon, Gabriel Meric ; Rankouhi, Behzad ; Steiner, Leo J. ; Mahadumrongkul, Puwadej ; Petry, George ; Thevamaran, Mythili ; Swader, Rob ; et al ( September 2019 , Journal of Medical Devices)

   Cerebral aneurysm clips are biomedical implants applied by neurosurgeons to re-approximate arterial vessel walls and prevent catastrophic aneurysmal hemorrhages in patients. Current methods of aneurysm clip production are labor intensive and time-consuming, leading to high costs per implant and limited variability in clip morphology. Metal additive manufacturing is investigated as an alternative to traditional manufacturing methods that may enable production of patient-specific aneurysm clips to account for variations in individual vascular anatomy and possibly reduce surgical complication risks. Relevant challenges to metal additive manufacturing are investigated for biomedical implants, including material choice, design limitations, postprocessing, printed material properties, and combinedmore »production methods. Initial experiments with additive manufacturing of 316 L stainless steel aneurysm clips are carried out on a selective laser melting (SLM) system. The dimensions of the printed clips were found to be within 0.5% of the dimensions of the designed clips. Hardness and density of the printed clips (213 ± 7 HV1 and 7.9 g/cc, respectively) were very close to reported values for 316 L stainless steel, as expected. No ferrite and minimal porosity is observed in a cross section of a printed clip, with some anisotropy in the grain orientation. A clamping force of approximately 1 N is measured with a clip separation of 1.5 mm. Metal additive manufacturing shows promise for use in the creation of custom aneurysm clips, but some of the challenges discussed will need to be addressed before clinical use is possible.« less