Effect of "ColdArc" WAAM Regime and Arc Torch Weaving on Microstructure and Properties of As-Built and Subtransus Quenched Ti-6Al-4V.

Defect-free thin-walled samples were built using wire arc additive manufacturing (WAAM) combined with the "coldArc" deposition technique by feeding a Ti-6Al-4V welding wire and using two deposition strategies, namely with and without the welding torch weaving. The microstructures formed in these samples were examined in relation to mechanical characteristics. The arc torch weaving at 1 Hz allowed us to interfere with the epitaxial growth of the ß-Ti columnar grains and, thus, obtain them a lower aspect ratio. Upon cooling, the α/α'+ß structure was formed inside the former ß-Ti grains, and this structure proved to be more uniform as compared to that of the samples built without the weaving. The subtransus quenching of the samples in water did not have any effect on the structure and properties of samples built with the arc torch weaving, whereas a more uniform grain structure was formed in the sample built without weaving. Quenching resulted also in a reduction in the relative elongation by 30% in both cases.

Microstructures and Phases in Electron Beam Additively Manufactured Ti-Al-Mo-Zr-V/CuAl9Mn2 Alloy.

Electron beam additive manufacturing from dissimilar metal wires was used to intermix 5, 10 and 15 vol.% of Ti-Al-Mo-Z-V titanium alloy with CuAl9Mn2 bronze on a stainless steel substrate. The resulting alloys were subjected to investigations into their microstructural, phase and mechanical characteristics. It was shown that different microstructures were formed in an alloy containing 5 vol.% titanium alloy, as well as others containing 10 and 15 vol.%. The first was characterized by structural components such as solid solution, eutectic intermetallic compound TiCu2Al and coarse grains of γ1-Al4Cu9. It had enhanced strength and demonstrated steady oxidation wear in sliding tests. The other two alloys also contained large flower-like Ti(Cu,Al)2 dendrites that appeared due to the thermal decomposition of γ1-Al4Cu9. This structural transformation resulted in catastrophic embrittlement of the composite and changing of wear mechanism from oxidative to abrasive.

Evidence of Tribological Adaptation Controlled by Tribosynthesis of FeWO4 on an WC-Reinforced Electron Beam M2 Steel Coating Rubbed against a HSS Disk in a Range of Sliding Speeds.

In the present work, the tribological experiments on sliding the electron beam composite M2+WC coating have been carried out with characterization of the sample microstructures and phases both before and after the testing using metallography, SEM, EDS, and XRD. The sliding in the speed range 0.8-3.6 m/s resulted in simultaneous reduction in both wear rate and coefficient of friction with the sliding speed. Investigations showed that such a tribological adaptation was due to the tribochemical generation of lubricative FeWO4 and Fe2WO6 mixed oxides and the generation of a mechanically mixed composite layer on the worn surfaces that consisted of carbide fragments, an oxidized metal matrix, and was lubricated by in-situ formed mixed iron-tungsten oxides.

Macro- and Microstructure of In Situ Composites Prepared by Friction Stir Processing of AA5056 Admixed with Copper Powders.

This paper is devoted to using multi-pass friction stir processing (FSP) for admixing 1.5 to 30 vol.% copper powders into an AA5056 matrix for the in situ fabrication of a composite alloy reinforced by Al-Cu intermetallic compounds (IMC). Macrostructurally inhomogeneous stir zones have been obtained after the first FSP passes, the homogeneity of which was improved with the following FSP passes. As a result of stirring the plasticized AA5056, the initial copper particle agglomerates were compacted into large copper particles, which were then simultaneously saturated by aluminum. Microstructural investigations showed that various phases such as α-Al(Cu), α-Cu(Al) solid solutions, Cu3Al and CuAl IMCs, as well as both S and S'-Al2CuMg precipitates have been detected in the AA5056/Cu stir zone, depending upon the concentration of copper and the number of FSP passes. The number of IMCs increased with the number of FSP passes, enhancing microhardness by 50-55%. The effect of multipass FSP on tensile strength, yield stress and strain-to-fracture was analyzed.

In-Situ Al-Mg Alloy Base Composite Reinforced by Oxides and Intermetallic Compounds Resulted from Decomposition of ZrW2O8 during Multipass Friction Stir Processing.

In the presented work, the effect of friction stir processing admixing the zirconium tungstate ZrW2O8 powder on the microstructure, mechanical and tribological properties of the AA5056 Al-Mg alloy stir zone has been studied. The FSP resulted in obtaining dense composite stir zones where α-ZrW2O8 underwent the following changes: (i) high-temperature transformation into metastable ß'-ZrW2O8 and (ii) decomposition into WO3 and ZrO2 oxides followed by the formation of intermetallic compounds WAl12 and ZrAl3. These precipitates served as reinforcing phases to improve mechanical and tribological characteristics of the obtained fine-grained composites. The reduced values of wear rate and friction coefficient are due to the combined action the Hall-Petch mechanism and reinforcement by the decomposition products, including Al2O3, ZrO2, ß'-ZrW2O8 and intermetallic compounds such as WAl12 and ZrAl3. Potential applications of the above-discussed composites maybe related to their improved tribological characteristics, for example in aerospace and vehicle-building industries.

Features of the Macro-, Micro-, and Fine Structure of the Nickel Superalloy Product Material Formed by the Method of Electron Beam Additive Manufacturing.

In the present work, the products in the form of vertical walls were made of heat-resistant nickel-based superalloy ZhS32 via the method of electron beam additive technology. Unidirectional printing strategy was applied. The effect of heat input and 3D printing strategy on the macrostructure, dimensions, and morphology of microstructure elements was established. It was shown that the additive product material has a directed macrostructure. The only exclusion was the final layer with a thickness of no more than 3.5 mm. The directed macrostructure consisted of dendrites oriented predominantly along the crystallographic direction {001} of the primary dendrite arms. The misorientation of the dendrite axes did not exceed 9 degrees. The angle between the predominant dendrite growth direction and the normal to the substrate was 23 degrees. The average primary dendrite arms' spacing increased monotonically from 16 µm at 5 mm from the substrate to 23 µm in the final layers of the product material (the overall height was 41 mm). It was found that the average size of γ' (Ni3Al)-phase precipitations in the form of nanoscale and submicrocrystalline cuboids varied in the range of 76 to 163 nm depending on the distance from the substrate. The size of γ'-phase precipitations reached a maximum at about 30 mm from the substrate, while in the final layers of the product material, the average cuboid size did not exceed 135 nm. Extreme dependence of the size of γ'-phase precipitations on the height of the product followed from a combination of a given monotonic decrease in heat input and heat accumulation in the product material as it formed, as did additional heat removal by means of radiation during formation of the final layer of the product without re-melting. Chemical elements of the austenitic steel substrate material were not detected in the product material more than 8 mm from the substrate. There were no macrodefects, such as voids, in the entire volume of the product material.

Aluminum Bronze/Udimet 500 Composites Prepared by Electron-Beam Additive Double-Wire-Feed Manufacturing.

Novel composite CuA19Mn2/Udimet-500 alloy walls with different content of the Udimet 500 were built using electron-beam double-wire-feed additive manufacturing. Intermixing both metals within the melted pool resulted in dissolving nickel and forcing out the aluminum from bronze. The resulting phases were NiAl particles and grains, M23C6/NiAl core/shell particles and Cu-Ni-Al solid solution. Precipitation of these phases resulted in the increased hardness and tensile strength as well as reduced ductility of the composite alloys. Such a hardening resulted in improving the wear resistance as compared to that of source aluminum bronze.

In Situ Intermetallics-Reinforced Composite Prepared Using Multi-Pass Friction Stir Processing of Copper Powder on a Ti6Al4V Alloy.

Multi-pass friction stir processing (FSP) was used to obtain a titanium alloy/copper hybrid composite layer by intermixing copper powder with a Ti6Al4V alloy. A macrostructurally inhomogeneous stir zone was obtained with both its top and middle parts composed of fine dynamically recrystallized α- and ß-Ti grains, as well as coarse intermetallic compounds (IMCs) of Ti2Cu and TiCu2, respectively. Some ß grains experienced ß â†’ α decomposition with the formation of acicular α-Ti microstructures either inside the former ß-Ti grains or at their grain boundaries. Both types of ß â†’ α decomposition were especially clearly manifested in the vicinity of the Ti2Cu grains, i.e., in the copper-lean regions. The middle part of the stir zone additionally contained large dislocation-free ß-Ti grains that resulted from static recrystallization. Spinodal decomposition, as well as solid-state amorphization of copper-rich ß-Ti grains, were discovered. The FSPed stir zone possessed hardness that was enhanced by 25% as compared to that of the base metal, as well as higher strength, ductility, and wear resistance than those obtained using four-pass FSPed Ti6Al4V.

Features of Microstructure and Texture Formation of Large-Sized Blocks of C11000 Copper Produced by Electron Beam Wire-Feed Additive Technology.

The paper investigated the possibility of obtaining large-sized blocks of C11000 copper on stainless steel substrates via electron beam wire-feed additive technology. The features of the microstructure and grain texture formation and their influence on the mechanical properties and anisotropy were revealed. A strategy of printing large-sized C11000 copper was determined, which consists of perimeter formation followed by the filling of the internal layer volume. This allows us to avoid the formation of defects in the form of drops, underflows and macrogeometry disturbances. It was found that the deposition of the first layers of C11000 copper on a steel substrate results in rapid heat dissipation and the diffusion of steel components (Fe, Cr and Ni) into the C11000 layers, which promotes the formation of equiaxed grains of size 8.94 ± 0.04 µm. As the blocks grow, directional grain growth occurs close to the <101> orientation, whose size reaches 1086.45 ± 57.13 µm. It is shown that the additive growing of large-sized C11000 copper leads to the anisotropy of mechanical properties due to non-uniform grain structure. The tensile strength in the opposite growing direction near the substrate is 394 ± 10 MPa and decreases to 249 ± 10 MPa as the C11000 blocks grows. In the growing direction, the tensile strength is 145 ± 10 MPa.

Microstructure and Corrosion Resistance of AA4047/AA7075 Transition Zone Formed Using Electron Beam Wire-Feed Additive Manufacturing.

A gradient transition zone was obtained using electron beam deposition from AA4047 wire on AA7075 substrate and characterized for microstructures, tensile strength and corrosion resistance. The microstructure of the transition zone was composed of aluminum alloy grains, Al/Si eutectics and Fe-rich and Si-rich particles. Such a microstructure provided strength comparable to that of AA7075-T42 substrate but more intense corrosion due to the higher amount of anodic Mg2Si particles. The as-deposited AA4047 zone formed above the transition zone was composed of aluminum alloy dendrites and interdendritic Al/Si eutectics with low mechanical strength and high corrosion potential.