An official website of the United States government
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.
more »
« less
This content will become publicly available on March 31, 2026
The Effects of Inoculation on the Weldability of 6061 Aluminum Processed with GMA-DED
The weldability of plain and inoculated 6061 aluminum processed with gas metal arc directed energy deposition (GMA-DED) was evaluated and compared to wrought 6061. Autogenous gas tungsten arc welds of varying heat inputs were made, and the degree of solidification cracking was evaluated. The degree of cracking in the inoculated 6061 material was lower than that of plain GMA-DED and wrought 6061. Microstructure characterization revealed that the welds on the inoculated 6061 produced fine, equiaxed grains, whereas the plain 6061 showed coarse, columnar grains. A combination of heat transfer and solidification models were employed to predict the solidification morphology of the 6061 welds, which closely matched the experimental results in all cases. A model was developed to understand the effect of grain morphology on solidification cracking, and it was found that equiaxed grains shifted the critical liquid film range for cracking to lower solid fractions where thermal stresses are the lowest. However, cracking can be caused if sufficient external stresses are applied when the critical liquid film thickness is present during solidification of the equiaxed grain structure. This work provides insight into the role grain size and morphology control can have in suppressing solidification cracking of other aluminum alloys.
more »
« less
- Award ID(s):
- 2052819
- PAR ID:
- 10609306
- Publisher / Repository:
- Welding Journal
- Date Published:
- Journal Name:
- Welding Journal
- Volume:
- 104
- Issue:
- 5
- ISSN:
- 0043-2296
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Abstract Gas metal arc directed energy deposition (GMA-DED) has potential for the power generation industry to reduce both time and cost since larger and more complex part geometries can be constructed compared to the typical subtractive methods. The performance of GMA-DED builds can be influenced by the deposition method, resulting microstructure, and formation of defects or secondary phases in the final component. Previous work in the literature evaluated the mechanical properties of GMA-DED builds for a range of austenitic stainless steels, however there is limited data on the high temperature mechanical behavior. This work evaluated the high temperature creep properties of GMA-DED builds constructed with type 316H, 316L, 316LSi, and 16-8-2 stainless steels at 650 °C, 750 °C and 825 °C. The alloy with longest time to rupture for a given stress varied depending on test temperature. Creep damage accumulation at grain boundaries was observed along with grain boundary precipitates which likely aided in damage accumulation. Evaluating the creep properties with the Larson-Miller parameter showed the majority of results fell within the scatter band of creep performance for wrought 316 alloys, indicating the GMA-DED process may be suitable for use in advanced energy systems.more » « less
-
null (Ed.)The susceptibility of austenitic, ferritic, and duplex stain-less steels to solidification cracking was evaluated by the new Transverse Motion Weldability (TMW) test. The focus was on austenitic stainless steels. 304L and 316L were least susceptible, 321 was significantly more susceptible, and 310 was much more susceptible. However, some 321 welds were even less susceptible than 304L welds. These 321 welds were found to have much finer grains to better resist solidification cracking. Quenching 321 during welding revealed spontaneous grain refining could occur by heterogeneous nucleation. For 304L, 316L, and 310, a new explanation for the susceptibility was proposed based on the continuity of the liquid between columnar dendrites; a discontinuous, isolated liquid allows bonding between dendrites to occur early to better resist cracking. In 304L and 316L, the dendrite-boundary liquid was discontinuous and isolated, as revealed by quenching. The liquid was likely depleted by both fast back diffusion into -dendrites (body-centered cubic) and the L + + reaction, which consumed L while forming . In 310, however, the dendrites were separated by a continuous liquid that prevented early bonding between them. Back diffusion into -dendrites (face-centered cubic) was much slower, and the L + + reaction formed little . Quenching also revealed skeletal/lacy formed in 304L and 316L well after solidification ended; thus, skeletal/lacy did not resist solidification cracking, as had been widely believed for decades. The TMW test further demonstrated that both more sulfur and slower welding can increase susceptibility.more » « less
-
Nickel-based alloys, Alloys 625 and 718, are widely used in the aerospace industry due to their excellent corrosion resistance and high strength at elevated temperatures. Recently, these alloys have been utilized to manufacture rocket engine components using additive manufacturing (AM) technologies such as laser powder bed fusion (LPBF) and powder-blown laser-based directed energy deposition (DED). These technologies offer faster and more cost-effective production while enabling the fabrication of near-net-shape parts that are subsequently joined by welding. However, solidification cracking susceptibility varies significantly between AM and conventionally processed materials, and limited weldability characterization has been conducted on AM-fabricated materials. This study assesses the weld solidification cracking susceptibility of Alloys 625 and 718 produced by wrought (mill-rolled), LPBF, and DED using transverse varestraint testing, Scheil-Gulliver simulations, the Crack Susceptibility Index (CSI), and the Flow Resistance Index (FRI). Transverse varestraint testing revealed that AM parts exhibited higher susceptibility due to the presence of larger and elongated grains in the fusion zone, affecting the weld solidification cracking response. In Alloy 625, the LPBF condition exhibited the highest maximum crack distance (MCD) of 2.35 ± 0.16 mm, compared to 1.56 ± 0.06 mm for wrought and 1.72 ± 0.10 mm for DED. Similarly, in Alloy 718, the DED condition showed the highest MCD of 2.93 ± 0.41 mm, while the wrought condition had an MCD of 2.01 ± 0.12 mm, and the LPBF condition reached 3.01 ± 0.33 mm at 5 % strain, without a clearly defined saturation strain. Although wrought materials demonstrated greater resistance to solidification cracking, solidification simulations did not correlate with the experimental testing, as they do not account for microstructural and mechanical factors, relying solely on chemistry.more » « less
-
Inconel 718 is a widely popular aerospace superalloy known for its high-temperature performance and resistance to oxidation, creep, and corrosion. Traditional manufacturing methods, like casting and powder metallurgy, face challenges with intricate shapes that can result in porosity and uniformity issues. On the other hand, Additive Manufacturing (AM) techniques such as Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) can allow the creation of intricate single-part components to reduce weight and maintain structural integrity. However, AM parts often exhibit directional solidification, leading to anisotropic properties and potential crack propagation sites. To address this, post-processing treatments like HIP and heat treatment are necessary. This study explores the effects of the raster and stochastic spot melt scanning strategies on the microstructural and mechanical properties of IN718 parts fabricated using Electron Beam Powder Bed Fusion (EB-PBF). This research demonstrates that raster scanning produces columnar grains with higher mean aspect ratios. Stochastic spot melt scanning facilitates the formation of equiaxed grains, which enhances microstructural refinement and lowers anisotropy. The highest microstructural values were recorded in the raster-produced columnar grain structure. Conversely, the stochastic melt-produced transition from columnar to equiaxed grain structure demonstrated increased hardness with decreasing grain size; however, the hardness of the smallest equiaxed grain structure was slightly less than that of the columnar grain structure. These findings underscore the vital importance of scanning strategies in optimizing the EB-PBF process to enhance material properties.more » « less
