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An operando synchrotron study on the effect of wire melting state on solidification microstructures of Inconel 718 in wire-laser directed energy deposition
Directed energy deposition (DED) with a coaxial wire-laser configuration has gained significant attention in recent years for the production of large-scale metallic components because of its low directional dependence, fast deposition rate, high feedstock efficiency, and low manufacturing costs. This work studies the coaxial wire-laser DED process of Inconel 718 alloy under a stable deposition condition with a relatively low input volumetric energy density (55.5J/mm 3 ). Post characterization reveals a cluster of refined grains at the center-bottom region of the as-printed track. Operando high-energy synchrotron X-ray experiments and multi-physics modeling are applied innovatively to study the fundamental mechanism responsible for the formation of this microstructure. The X-ray diffraction experiment provides direct evidence, which is supported by the simulation, that the feeding wire can reach the melt pool bottom and release solid particles (primarily carbides) near the mushy zone owing to insufficient melting. Consequently, these sub-micron sized particles suppress the growth of large columnar grains and cause the formation of unique microstructural heterogeneity. In conclusion, this discovery offers new opportunities for tailoring the solidification microstructure by controlling the melting state of the feedstock wire in DED process, in addition to commonly known factors such as the thermal gradient and solidification velocity.
GEANT4 Simulations on Faraday Cup Design for PIP-II Laser Wire Scanner System
The PIP-II accelerator upgrade at Fermilab represents a groundbreaking leap forward in high-energy physics research. This ambitious initiative involves enhancing Fermilab's accelerator complex by replacing the current linear accelerator with a warm front end (WFE) capable of accelerating H- beams up to 2.1 MeV. Subsequently, a superconducting linac further accelerates these beams up to 800 MeV. To precisely measure the transverse beam profile, a combination of traditional wire scanners at the WFE section and Laser wire scanners along the superconducting linac are planned for implementation. This investigation centers on refining the Faraday cup design for the PIP-II Laser wire scanners by utilizing GEANT4, a Monte Carlo simulation toolkit. Leveraging this method enables a comprehensive analysis of particle trajectories, energy deposition, secondary electron emission, backscattering, etc., facilitating optimization through adjustments to cup geometries, materials, and placement to maximize its efficiency.
Integrated top-down process and voxel-based microstructure modeling for Ti-6Al-4V in laser wire direct energy deposition process
Laser-wire metal additive manufacturing (AM) is one of the ideal direct energy deposition (DED) processes for creating large-scale parts with a medium level of complexity. However, the DED process involves complex thermal signatures and wide length scales making the fabrication of realistic AM components and part qualification often reliant on experimental trial-and-error optimization. While experimental measurements over the full volume of a part are valuable and necessary, measuring the entire area of a part is significantly laborious and practically infeasible, particularly for large parts in terms of cost and rapid qualification. Therefore, in this work, we developed an effective thermal and microstructure modeling framework based on the Johnson–Mehl-Avrami-Kolmogorov (JMAK) and Koistinen & Marburger (KM) models through a top-down approach that considers plate distortion-affected thermal profiles. A voxel-by-voxel simulation method is used to predict individual phase fractions of Ti-6Al-4 V. The predicted results were validated through detailed metallurgical measurements. A combined voxel-by-voxel approach with a sparse data reconstruction technique produced a near-perfect reconstruction of the original data. This approach anticipates a significant reduction in data points and computation time and resources. Lastly, we conclude with potential extensions of this work to other modeling efforts.
Geant4-based Analysis of Faraday Cup Performance for PIP-II Laser Wire Scanner System
The Proton Improvement Plan-II (PIP-II) accelerator upgrade at Fermilab marks a significant advancement in high-energy physics research. This initiative aims to enhance Fermilab's accelerator complex by replacing the existing linear accelerator (linac) with a warm front end (WFE) capable of accelerating H- beams up to 2.1 MeV. Subsequently, a superconducting linac (SCL), that further accelerates these beams up to 800 MeV. To accurately measure the transverse beam profile, traditional wire scanners will be utilized in the WFE section, while Laser wire scanners will be implemented along the SCL. The Faraday cup for the Laser wire scanners has been designed using the GEANT4 simulation toolkit. This poster presents a detailed analysis of its performance along the SCL, focusing on electron absorption, secondary electron emission, backscattering, etc.
Hybrid additive manufacturing of AISI 316L via asynchronous powder and hot-wire laser directed energy deposition
Hybrid Additive Manufacturing (AM) offers a way to leverage the advantages of different AM technologies, enabling the efficient production of sizeable parts without compromising material properties or geometric complexity capabilities. This study presents an asynchronous hybrid Directed Energy Deposition (DED) strategy employing laser powder DED and laser hot-wire DED. AISI 316L parts comprising multiple powder and wire segments were fabricated with optional machining on AISI 316L substrates to investigate how quality is impacted by (i) alternative process sequences (laser powder DED followed by laser hot-wire DED and vice versa), (ii) machined vs. as-printed interfacial conditions, and (iii) material deposition on top vs. alongside previously built segments. Optical microscopy, X-ray computed tomography, and Vickers hardness were used to characterize the morphology and microstructure of the parts, localized porosity and lack of fusion defects, bulk density, and mechanical properties. Interfacial machining was necessary for dimensional control but promoted lack of fusion voids, resulting in a 99.71 ± 0.01% dense part. As-printed interfaces resulted in a denser part (99.82 ± 0.02%) at the expense of dimensional accuracy. The hardness of the parts with as-printed and machined interfaces was 196 ± 0.37 HV and 192 ± 0.40 HV, respectively, compared to 156 ± 1.4 HV for the substrate. Depositing powder alongside or on top of wire sections resulted in interfaces with a hardness of 217 ± 2.2 HV, compared to 185 ± 3.4 HV for the wire-powder interfaces.
Location-Specific Microstructures and Properties of Haynes 282 Alloy with Laser-Wire DED Processing
In this work, the location-specific microstructures in terms of grain morphology, texture, γ′ precipitates, carbides, and residual strains were investigated in a series of laser-wire direct energy deposition (LW-DED) Haynes 282 alloys with varied processing parameters. A bimodal grain distribution was found in these as-printed and heat-treated alloys with columnar grains within the layers and fine equiaxed grains at the interlayer regions. Dominant <001> texture along the build direction with more obvious <111> orientation preference exists at the bottom layers, compared to the top layers. The gradient γ′-precipitates size distribution contributes predominantly to the observed gradient hardness distribution in the as-printed samples. The heat-treated 282 exhibit comparable yield strengths to those conventionally-processed counterparts, while the observed small deviation in their yield strengths is attributed to the Hall-Petch effect. This work establishes the correlation between location-specific microstructures and mechanical properties, providing valuable insights into future printing parameters and heat-treatment optimization.
Geant4 Simulations on Faraday Cup Design for PIP-II Laser Wire Scanner System
The Proton Improvement Plan-II (PIP-II) accelerator upgrade at Fermilab represents a groundbreaking leap forward in high-energy physics research. This ambitious initiative involves enhancing Fermilab's accelerator complexby replacing the current linear accelerator (linac) with awarm front end (WFE) capable of accelerating H- beamsup to 2.1 MeV. Subsequently, a superconducting linac further accelerates these beams up to 800 MeV. To preciselymeasure the transverse beam profile, a combination of traditional wire scanners at the WFE section and Laser wirescanners along the superconducting linac are planned forimplementation. This investigation is centered on refiningthe Faraday cup design for the PIP-II Laser wire scannersby utilizing GEANT4, a Monte Carlo simulation toolkit.Leveraging this method enables a comprehensive analysisof particle trajectories, energy deposition, secondary particle emission, backscattering, etc., facilitating optimizationthrough adjustments to cup geometries, materials, andplacement to maximize its efficacy in beam diagnostics.
Time-Dependent 600 °C Post-Weld Heat Treatment Response of Laser-Wire-Directed Energy Deposited Austenitic Stainless Steel Claddings on Carbon Steel
Austenitic stainless steel overlay claddings are often used to protect nuclear reactor pressure vessels from corrosion. Arc welding processes are traditionally employed, which require a high heat input to bond the dissimilar metals, creating a large heat-affected zone and high residual stress that demands a lengthy stress-relieving post-weld heat treatment, up to 48 hours. High energy beam (e.g., laser, electron beam) directed energy deposition-based overlay cladding processes show promise for fabricating claddings with superior performance compared to arc welded ones because of their localized heat input; however, their necessity and time of post-weld heat treatment are currently unclear. In this research, we investigate the time dependence of a 600 C stress-relieving post-weld heat treatment of austenitic stainless steel clad on low carbon steel by laser-wire-directed energy deposition, comparing the microstructure and mechanical properties of the as-fabricated condition to 2-, 10-, and 48-hour heat treatment times. Diffusion simulations and microscopy show a gradual carburization of the stainless steel cladding and decarburization of the heat-affected zone/base metal. Nanoindentation testing shows up to a 1.8–2.69 embrittlement in the cladding and a 0.33 to 0.69 softening in the heat-affected zone after the 48-hour post-weld heat treatment. Tensile testing of the cladding composites reveals that increasing post-weld heat treatment time raises clad cracking susceptibility due to intergranular carbide formation and shows that laser-wire-directed energy deposition claddings may not require post-weld heat treatment.
Location-specific microstructures and properties of Haynes 282 with laser-wire DED processing
Poster presentation at the 2024 FECM/NETL Spring R&D Project Review Meeting on Location-specific microstructures and properties of Haynes 282 with laser-wire DED processing.
Tailoring material microstructure and property in wire-laser directed energy deposition through a wiggle deposition strategy
Developing effective strategies to directly control material microstructure, property, and anisotropy is an active research area in metal additive manufacturing. This work develops a wiggle deposition pattern for wire-laser directed energy deposition (DED) of 316L stainless steel (SS) to modify the solidification texture, particularly in the building direction, in as-deposited samples. Through multi-physics simulation, operando near-infrared imaging, and synchrotron x-ray characterization, it is found that the wiggle deposition strategy induces highly dynamic melt flow and oscillating thermal gradient in the melt pool, which is responsible for the variation of preferable grain growth direction and crystallographic texture in the sample. The specific texture reduces the anisotropy in the tensile strength of as-printed 316L SS samples cut along different directions. Also, it largely increases the ductility along the build direction. Crystal plasticity simulation is performed to correlate the sample texture with mechanical property. In conclusion, this work offers a unique approach for tailoring local properties through the control of melt pool instability by applying different tool paths.
Laser scattering by submicron droplets formed during the electrical explosion of thin metal wires
Abstract This paper presents the results of studying dispersed media formation during the electrical explosion of thin metal wires in vacuum by using low-current generators (~1–10 kA). Particular attention is paid to the analysis of the composition and structure of the corresponding explosion products as well as to the problem of their visualization using simultaneous laser interferometry and shadow imaging at two wavelengths (1.064 µ m and 0.532 µ m). Our findings indicate the important role in the visualization of the explosion products that belongs to multiple scattering by submicron droplets of dense condensed matter, which are mixed with metal vapor. The hypothesis on the existence of submicron droplets in the products of exploding metal wires correlates with the results obtained by soft x-ray radiography combined with a laser probing technique. Taking into account the multiple scattering by submicron droplets, it is possible to significantly clarify the parameters of the explosion products visualized via laser probing techniques as well as to gain a deeper insight into the physics behind the electrical wire explosion.
4D transverse phase space tomography of an operational hydrogen ion beam via noninvasive 2D measurements using laser wires
Not Available
Longitudinal bunch profile measurement of operational H − beam using laser wire and virtual slit
Not Available
Process Development of Laser-Wire DED of Haynes 282 Ni-based Superalloy
TMS 2022 On Demand, Virtual, March 14, 2022
Recent progress in laser wire-based H- beam diagnostics at the SNS linac
Laser wire has been used for nonintrusive profile and emittance measurements of operational hydrogen ion (H-) beam at the SNS linac. In this talk, we will describe the following recent developments in the laser wire system. 1) An upgraded light source and laser transport line which enables novel measurement capabilities including longitudinal profile measurement and high-energy proton beam extraction over potentially an entire macropulse. 2) A dual-detector emittance measurement scheme that boosted the dynamic range by an order of magnitude. 3) Design and implementation laser-wire-based nonintrusive longitudinal phase space measurement system.