ABSTRACT
Coarse columnar grains and heterogeneously distributed phases commonly form in metallic alloys produced by three-dimensional (3D) printing and are often considered undesirable because they can impart nonuniform and inferior mechanical properties. We demonstrate a design strategy to unlock consistent and enhanced properties directly from 3D printing. Using Ti-5Al-5Mo-5V-3Cr as a model alloy, we show that adding molybdenum (Mo) nanoparticles promotes grain refinement during solidification and suppresses the formation of phase heterogeneities during solid-state thermal cycling. The microstructural change because of the bifunctional additive results in uniform mechanical properties and simultaneous enhancement of both strength and ductility. We demonstrate how this alloy can be modified by a single component to address unfavorable microstructures, providing a pathway to achieve desirable mechanical characteristics directly from 3D printing.
ABSTRACT
Additive manufacturing (AM) creates digitally designed parts by successive addition of material. However, owing to intrinsic thermal cycling, metallic parts produced by AM almost inevitably suffer from spatially dependent heterogeneities in phases and mechanical properties, which may cause unpredictable service failures. Here, we demonstrate a synergistic alloy design approach to overcome this issue in titanium alloys manufactured by laser powder bed fusion. The key to our approach is in-situ alloying of Ti-6Al-4V (in weight per cent) with combined additions of pure titanium powders and iron oxide (Fe2O3) nanoparticles. This not only enables in-situ elimination of phase heterogeneity through diluting V concentration whilst introducing small amounts of Fe, but also compensates for the strength loss via oxygen solute strengthening. Our alloys achieve spatially uniform microstructures and mechanical properties which are superior to those of Ti-6Al-4V. This study may help to guide the design of other alloys, which not only overcomes the challenge inherent to the AM processes, but also takes advantage of the alloy design opportunities offered by AM.
ABSTRACT
Austenitizing temperature is one decisive factor for the mechanical properties of medium carbon martensitic stainless steels (MCMSSs). In the present work, the effects of austenitizing temperature (1000, 1020, 1040 and 1060 °C) on the microstructure and mechanical properties of MCMSSs containing metastable retained austenite (RA) were investigated by means of electron microscopy, X-ray diffraction (XRD), as well as tensile and impact toughness tests. Results suggest that the microstructure including an area fraction of undissolved M23C6, carbon and chromium content in matrix, prior austenite grain size (PAGS), fraction and composition of RA in studied MCMSSs varies with employed austenitizing temperature. By optimizing austenitizing temperature (1060 °C for 40 min) and tempering (250 °C for 30 min) heat treatments, the MCMSS demonstrates excellent mechanical properties with the ultimate tensile strength of 1740 ± 8 MPa, a yield strength of 1237 ± 19 MPa, total elongation (ductility) of 10.3 ± 0.7% and impact toughness of 94.6 ± 8.0 Jcm-2 at room temperature. The increased ductility of alloys is mainly attributed to the RA with a suitable stability via a transformation-induced plasticity (TRIP) effect, and a matrix containing reduced carbon and chromium content. However, the impact toughness of MCMSSs largely depends on M23C6 carbides.
