The Influence of Layer Thickness on the Microstructure and Mechanical Properties of M300 Maraging Steel Additively Manufactured by LENS® Technology.

This work investigates the effect of layer thickness on the microstructure and mechanical properties of M300 maraging steel produced by Laser Engineered Net Shaping (LENS®) technique. The microstructure was characterized using light microscopy (LM) and scanning electron microscopy (SEM). The mechanical properties were characterized by tensile tests and microhardness measurements. The porosity and mechanical properties were found to be highly dependent on the layer thickness. Increasing the layer thickness increased the porosity of the manufactured parts while degrading their mechanical properties. Moreover, etched samples revealed a fine cellular dendritic microstructure; decreasing the layer thickness caused the microstructure to become fine-grained. Tests showed that for samples manufactured with the chosen laser power, a layer thickness of more than 0.75 mm is too high to maintain the structural integrity of the deposited material.

Calorimetric Studies of Magnesium-Rich Mg-Pd Alloys.

Solution calorimetry with liquid aluminum as the bath was conducted to measure the enthalpy of a solution of magnesium and palladium as well as the standard formation enthalpies of selected magnesium-palladium alloys. These alloys were synthesized from pure elements, which were melted in a resistance furnace that was placed in a glove box containing high-purity argon and a very low concentration of impurities, such as oxygen and water vapor. A Setaram MHTC 96 Line evo drop calorimeter was used to determine the energetic effects of the solution. The enthalpies of the Mg and Pd solutions in liquid aluminum were measured at 1033 K, and they equaled -8.6 ± 1.1 and -186.8 ± 1.1 kJ/mol, respectively. The values of the standard formation enthalpy of the investigated alloys with concentrations close to the Mg6Pd, ε, Mg5Pd2, and Mg2Pd intermetallic phases were determined as follows: -28.0 ± 1.2 kJ/mol of atoms, -32.6 ± 1.6 kJ/mol of atoms, -46.8 ± 1.4 kJ/mol of atoms, and -56.0 ± 1.6 kJ/mol of atoms, respectively. The latter data were compared with existing experimental and theoretical data from the literature along with data calculated using the Miedema model.

The Tribaloy T-800 Coatings Deposited by Laser Engineered Net Shaping (LENSTM).

A Tribaloy family of alloys (CoMoCrSi) are characterized by a substantial resistance to wear and corrosion within a wide range of temperatures. These properties are a direct result of their microstructure including the presence of Laves phase in varying proportions. Tribaloy T-800 exhibits the highest content of Laves phase of all other commercial Tribaloy alloys, which provides high hardness and wear resistance. On the other hand, a large content of the Laves phase brings about a high sensitivity to brittle fracture of this alloy. The main objective of this work was a development of the Tribaloy T-800 coatings on the Ni-based superalloy substrate (RENE 77), which employs a Laser Engineered Net Shaping (LENSTM) technique. Technological limitations in this process are susceptibility of T-800 to brittle fracture as well as significant thermal stresses due to rapid cooling, which is an inherent attribute of laser techniques. Therefore, in this work, a number of steps that optimized the LENSTM process and improved the metallurgical soundness of coatings are presented. Employing volume and local substrate pre-heating resulted in the formation of high quality coatings devoid of cracks and flaws.