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Abstract The solidification microstructures of plain and inoculated 6061 aluminum builds manufactured with gas metal arc-directed energy deposition were studied with a combination of models and experiments. Electron back-scatter diffraction (EBSD) showed that the plain 6061 build had large, columnar grains with intergranular solidification cracking, while the inoculated build had a near-equiaxed, fine grain microstructure with no solidification cracks. By combining EBSD and energy dispersive spectrometry, the inoculated build has been shown to have exhibited globular growth while the non-inoculated build displayed a dendritic microstructure. A combination of heat transfer and modified grain morphology models were employed to predict the solidification morphology of the 6061 builds, which closely matched experimental results. A modification is proposed to the criterion marking the transition from globular to dendritic growth that better matches experimental results in this work. The results of this study are expected to provide improved methods to predict solidification microstructure for the development of new materials and processing parameters for additive manufacturing.
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Investigations of Microstructure and Mechanical Properties in Wire + Arc Additively Manufactured Niobium–Zirconium Alloy
Herein, the feasibility of the gas tungsten arc welding‐based wire + arc additive manufacturing process for fabricating thin wall structures of niobium‐1 wt% zirconium (NbZr1) alloy is investigated. Three different heat input conditions (low, medium, and high) have been selected for fabricating it. The microstructure is characterized by using optical microscopy, scanning electron microscopy, X‐ray diffraction, energy‐dispersive spectroscopy, and electron backscattered diffraction (EBSD). The microstructure shows the columnar dendritic structure elongated in the build direction. No cracks or porosity are observed in the structure. Average Vickers hardness for low, medium, and high heat input conditions are 146.6, 162.1, and 163.5 HV, respectively. There is an increasing trend of microhardness value along the deposition height, which can be attributed to the difference in secondary dendritic arm spacing and the formation of precipitates. The tensile strength of the specimen is comparable to the conventional and additively manufactured structures. EBSD analysis confirms that possible subgrains are responsible for good mechanical properties at room temperature. In the majority of the tensile samples, the failure mechanism has been identified as a ductile fracture. The mechanical characteristics fluctuate with locations in each of the thin walls, suggesting anisotropy in the deposits.
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- Award ID(s):
- 2141905
- PAR ID:
- 10419348
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Advanced Engineering Materials
- Volume:
- 25
- Issue:
- 15
- ISSN:
- 1438-1656
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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