Search NASA⌕ Search

Engineering topics

Liou, Frank

Publications and source records attributed to Liou, Frank.

10 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Microstructure and Residual Stress in Functionally Graded 316L Stainless Steel/Inconel 625 Alloys Fabricated by Direct Energy Deposition

Functionally graded materials (FGMs) provide a unique solution to combine distinct properties within a single component to enhance its overall performance. Understanding the microstructure and residual stress distribution is particularly important as the material dissimilarity in FGMs can result in high residual stress that affects the mechanical integrity of structural components. Here, this work aims to study the microstructure and residual stress of additively manufactured FGMs and the effects of isothermal annealing. In this study, 316L stainless steel/Inconel 625 FGMs were built by direct energy deposition, and characterized by optical and electron microscopy as well as synchrotron-based X-ray diffraction. Our study reveals that thermal annealing at 500°C for 3 h has minimal effects on the microstructure and chemistry of the graded materials, but effectively relieves the residual stress and leads to a uniform distribution of residual stress.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Comparison of the Thermal Stability in Equal‐Channel‐Angular‐Pressed and High‐Pressure‐Torsion‐Processed Fe–21Cr–5Al Alloy

Nanostructured steels are expected to have enhanced irradiation tolerance and improved strength. However, they suffer from poor microstructural stability at elevated temperatures. In this study, Fe–21Cr–5Al–0.026C (wt%) Kanthal D (KD) alloy belonging to a class of (FeCrAl) alloys considered for accident‐tolerant fuel cladding in light‐water reactors is nanostructured using two severe plastic deformation techniques of equal‐channel angular pressing (ECAP) and high‐pressure torsion (HPT), and their thermal stability between 500–700 °C is studied and compared. ECAP KD is found to be thermally stable up to 500 °C, whereas HPT KD is unstable at 500 °C. Microstructural characterization reveals that ECAP KD undergoes recovery at 550 °C and recrystallization above 600 °C, while HPT KD shows continuous grain growth after annealing above 500 °C. Enhanced thermal stability of ECAP KD is from significant fraction (>50%) of low‐angle grain boundaries (GBs) (misorientation angle 2–15°) stabilizing the microstructure due to their low mobility. Small grain sizes, a high fraction (>80%) of high‐angle GBs (misorientation angle >15°) and accordingly a large amount of stored GB energy, serve as the driving force for HPT KD to undergo grain growth instead of recrystallization driven by excess stored strain energy.

Arivu, Maalavan↗
DOE OSTI2022

The Trajectory of Additively Manufactured Titanium Alloys with Superior Mechanical Properties and Engineered Microstructures

Additive manufacturing (AM) plays a crucial role in the manufacturing and development of advanced materials including titanium alloys for engineering applications. During the last two decades, a great deal of effort has been devoted to print titanium parts with desired properties. However, due to presence of non-equilibrium/metastable phases, anisotropic microstructure, and various porosities in the printed titanium alloys, achieving an excellent combination of mechanical properties has been challenging. Here this review paper aims to provide a comprehensive overview of multiple post-process and in-process approaches to achieve enhanced strength-ductility combinations by microstructure engineering. Approaches such as addition of alloying elements/nucleants, multi-step post heat treatment, in-situ heat treatment, forced inter-pass cooling, in situ peening/rolling, hybridizing microstructure, high-intensity acoustic vibration, thermo-hydrogen refinement of microstructure, deliberately introducing lack of fusion defects with subsequent hot isostatic pressing are discussed in detail. Finally, we conclude by highlighting the challenges associated with each method and potential areas of improvement that can pave the way to develop reliable components with enhanced performance.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of processing parameters and build orientation on microstructure and performance of AISI stainless steel 304L made with selective laser melting under different strain rates

Selective laser melting (SLM) process brings diverse potentials on geometry flexibility; therefore, it is more and more widespread to be employed in fabrication metal alloys served for industries. Nonetheless, a material characterization study is desired to carry on for better understanding the correlation among process, structure, microstructure, and performance. In the current study, the SLM fabricated AISI stainless steel 304L was fabricated with different process parameters and built orientations (horizontal, inclined, and vertical. The tensile behavior was evaluated under different strain rates (0.0001 /s, 0.001 /s, 0.01 /s, and 0.1 /s) and compared to the commercial cold-rolled and annealed counterpart. Grain structures, tensile strength, elongation-to-failure, strain rate sensitivity, work hardening, and fractographic analysis were evaluated in terms of the effect of energy density, build orientation, and strain rate. The output indicates the tensile strength increases with increasing strain rates. On the contrary, the elongation-to-failure shows a decreasing trend with strain rates. Tensile properties of specimens built in the horizontal and inclined orientations are more sensitive to strain rates due to the smaller dimension of grain structures. Tensile anisotropy depends on the energy input, where a high energy density could yield a strong build orientation-dependent anisotropy. Hall-Petch relationship is validated to explain the mechanical anisotropy in different built orientations for SLM alloys. The strain hardening exponent and work hardening rate are demonstrated to be positively correlated, and they increase with smaller grain sizes. The fine dimple features indicate the ductile fracture mode regardless of strain rates. The size of the ductile dimples seems to depend on the strain rates and build orientations.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Additive manufacturing of cobalt-based alloy on tool steel by directed energy deposition

Cladding hard-surfacing alloys on tool steel is an effective approach to enhance the surface properties of tool steel. In this study, a Co-based alloy was deposited on tool steel by Directed Energy Deposition (DED) following a three-factor three-level design of experiment matrix with varied laser power, scan speed, and powder flow rate. The microstructure of the deposits was characterized using scanning electron microscopy (SEM). The residual stress on the surface of the samples was measured by the X-ray diffraction (XRD) sin2? technique. The parameters that produced promising deposits were used to fabricate samples for tensile test, four-point bending test, Charpy impact test, and hardness measurement. Our result reveals that the processing parameters have a significant role in the residual stress of the coatings. Residual stress reduces with the increase of laser energy density. Cracks were found at samples with energy density below a threshold. Tensile testing of the coating/substrate combined structure reveals fracture at the coatings with an ultimate tensile strength of 633.9 ± 54.7 MPa. The bi-material interface survived the tensile test, indicating a strong interfacial bond. The four-point bending test of coating/substrate laminates shows an ultimate flexure strength of 860.6 ± 36.9 MPa. Cracks initiated from the coatings ignored the interface and penetrated the substrate, suggesting a solid bi-material bond. Charpy impact test shows the absorbed energy of coating/substrate laminates is more than doubled that of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A Novel Laser-Aided Machining and Polishing Process for Additive Manufacturing Materials with Multiple Endmill Emulating Scan Patterns

In additive manufacturing (AM), the surface roughness of the deposited parts remains significantly higher than the admissible range for most applications. Additionally, the surface topography of AM parts exhibits waviness profiles between tracks and layers. Therefore, post-processing is indispensable to improve surface quality. Laser-aided machining and polishing can be effective surface improvement processes that can be used due to their availability as the primary energy sources in many metal AM processes. While the initial roughness and waviness of the surface of most AM parts are very high, to achieve dimensional accuracy and minimize roughness, a high input energy density is required during machining and polishing processes although such high energy density may induce process defects and escalate the phenomenon of wavelength asperities. In this paper, we propose a systematic approach to eliminate waviness and reduce surface roughness with the combination of laser-aided machining, macro-polishing, and micro-polishing processes. While machining reduces the initial waviness, low energy density during polishing can minimize this further. The average roughness (Ra=1.11μm) achieved in this study with optimized process parameters for both machining and polishing demonstrates a greater than 97% reduction in roughness when compared to the as-built part.

42 ENGINEERING↗
NASA NTRS2015

Multiscale and Multiphysics Modeling of Additive Manufacturing of Advanced Materials

The objective of this proposed project is to research and develop a prediction tool for advanced additive manufacturing (AAM) processes for advanced materials and develop experimental methods to provide fundamental properties and establish validation data. Aircraft structures and engines demand materials that are stronger, useable at much higher temperatures, provide less acoustic transmission, and enable more aeroelastic tailoring than those currently used. Significant improvements in properties can only be achieved by processing the materials under nonequilibrium conditions, such as AAM processes. AAM processes encompass a class of processes that use a focused heat source to create a melt pool on a substrate. Examples include Electron Beam Freeform Fabrication and Direct Metal Deposition. These types of additive processes enable fabrication of parts directly from CAD drawings. To achieve the desired material properties and geometries of the final structure, assessing the impact of process parameters and predicting optimized conditions with numerical modeling as an effective prediction tool is necessary. The targets for the processing are multiple and at different spatial scales, and the physical phenomena associated occur in multiphysics and multiscale. In this project, the research work has been developed to model AAM processes in a multiscale and multiphysics approach. A macroscale model was developed to investigate the residual stresses and distortion in AAM processes. A sequentially coupled, thermomechanical, finite element model was developed and validated experimentally. The results showed the temperature distribution, residual stress, and deformation within the formed deposits and substrates. A mesoscale model was developed to include heat transfer, phase change with mushy zone, incompressible free surface flow, solute redistribution, and surface tension. Because of excessive computing time needed, a parallel computing approach was also tested. In addition, after investigating various methods, a Smoothed Particle Hydrodynamics Model (SPH Model) was developed to model wire feeding process. Its computational efficiency and simple architecture makes it more robust and flexible than other models. More research on material properties may be needed to realistically model the AAM processes. A microscale model was developed to investigate heterogeneous nucleation, dendritic grain growth, epitaxial growth of columnar grains, columnar-to-equiaxed transition, grain transport in melt, and other properties. The orientations of the columnar grains were almost perpendicular to the laser motion's direction. Compared to the similar studies in the literature, the multiple grain morphology modeling result is in the same order of magnitude as optical morphologies in the experiment. Experimental work was conducted to validate different models. An infrared camera was incorporated as a process monitoring and validating tool to identify the solidus and mushy zones during deposition. The images were successfully processed to identify these regions. This research project has investigated multiscale and multiphysics of the complex AAM processes thus leading to advanced understanding of these processes. The project has also developed several modeling tools and experimental validation tools that will be very critical in the future of AAM process qualification and certification.

Liou, Frank↗