T. Niendorf

Highly Anisotropic Steel Processed by Selective Laser Melting

For additive manufacturing of metals, selective laser melting can be employed. The microstructure evolution is directly influenced by processing parameters. Employing a high energy laser system, samples made from austenitic stainless steel were manufactured. The microstructure obtained is characterized by an extremely high degree of anisotropy featuring coarse elongated grains and a 〈001〉 texture alongside the build direction during processing. Eventually, the anisotropy of the microstructure drastically affects the monotonic properties of the current material.

On the fatigue behavior of ultrafine-grained interstitial-free steel

Abstract The present paper reports on the cyclic stress–strain response of body-centered cubic ultrafine-grained (UFG) interstitial-free (IF) steel severely plastically deformed at room temperature utilizing equal channel angular extrusion (ECAE). Low-cycle fatigue tests were conducted with various strain amplitudes and strain rates on samples obtained through different ECAE routes and number of ECAE passes in order to determine the optimum processing route(s) for improved fatigue response of this material. UFG IF steel is superior to its coarse grained counterpart under both monotonic and cyclic loading in terms of properties, such as stress ranges tolerated, strength levels attained, and the corresponding fatigue behavior. All UFG steels subjected to more than 4 ECAE passes exhibit stable cyclic stress–strain response. Moreover, it was shown that dynamic grain coarsening, which usually leads to cyclic softening in UFG materials, is not prevalent in the ECAE processed UFG IF steel. For representing the fatigue life of UFG IF steel, the parameter after Smith, Watson and Topper, which is an indication of energy dissipation per cycle, proved adequate while comparing materials obtained through different ECAE routes.

Corrosion fatigue behavior of a biocompatible ultrafine-grained niobium alloy in simulated body fluid

The present study reports on the corrosion fatigue behavior of ultrafine-grained (UFG) Niobium 2 wt-% Zirconium (NbZr) alloy in simulated body fluid (SBF). The alloy was processed using multipass equal channel angular processing at room temperature, resulting in a favorable combination of high strength and ductility along with superior biocompatibility and excellent corrosion resistance. Electrochemical measurements revealed stable passive behavior in SBF saline solutions, similar to conventional Ti-6Al-4V alloy. High-cycle fatigue tests showed no alteration in the crack initiation behavior due to the SBF environment, and an absence of pitting and corrosion products. More severe test conditions were obtained in the fatigue crack growth experiments in saline environments. Crack growth rates in UFG NbZr were marginally increased in SBF as compared to laboratory air at a constant test frequency of 20 Hz. Upon a 100 fold decrease in the test frequency, slightly higher crack growth rates were observed only in the near-threshold region. Such excellent corrosion and corrosion fatigue properties of UFG NbZr recommend it as an attractive new material for biomedical implants.

Microstructural Characterization and Mechanical Performance of Hot Work Tool Steel Processed by Selective Laser Melting

Microstructural characterization of hot work tool steel processed by selective laser melting was carried out. The findings shed light on the interrelationship between processing parameters and the microstructural evolution. It was found that the microstructure after layer-wise processing partially consists of metastable-retained austenite which transforms to martensite in a subsequent tensile test. This improves the mechanical properties of the hot work tool steel enabling direct application.

Fatigue Strength Prediction for Titanium Alloy TiAl6V4 Manufactured by Selective Laser Melting

Selective laser melting (SLM), as a metalworking additive manufacturing technique, received considerable attention from industry and academia due to unprecedented design freedom and overall balanced material properties. However, the fatigue behavior of SLM-processed materials often suffers from local imperfections such as micron-sized pores. In order to enable robust designs of SLM components used in an industrial environment, further research regarding process-induced porosity and its impact on the fatigue behavior is required. Hence, this study aims at a transfer of fatigue prediction models, established for conventional process-routes, to the field of SLM materials. By using high-resolution computed tomography, load increase tests, and electron microscopy, it is shown that pore-based fatigue strength predictions for a titanium alloy TiAl6V4 have become feasible. However, the obtained accuracies are subjected to scatter, which is probably caused by the high defect density even present in SLM materials manufactured following optimized processing routes. Based on thorough examination of crack surfaces and crack initiation sites, respectively, implications for optimization of prediction accuracy of the models in focus are deduced.

Anti-phase domains in cubic GaN

The existence of anti-phase domains in cubic GaN grown on 3C-SiC/Si (001) substrates by plasma-assisted molecular beam epitaxy is reported. The influence of the 3C-SiC/Si (001) substrate morphology is studied with emphasis on the anti-phase domains (APDs). The GaN nucleation is governed by the APDs of the substrate, resulting in equal plane orientation and the same anti-phase boundaries. The presence of the APDs is independent of the GaN layer thickness. Atomic force microscopy surface analysis indicates lateral growth anisotropy of GaN facets in dependence of the APD orientation. This anisotropy can be linked to Ga and N face types of the {111} planes, similar to observations of anisotropic growth in 3C-SiC. In contrast to 3C-SiC, however, a difference in GaN phase composition for the two types of APDs can be measured by electron backscatter diffraction, μ-Raman and cathodoluminescence spectroscopy.

Lattice Structures Manufactured by SLM: On the Effect of Geometrical Dimensions on Microstructure Evolution During Processing

Employing selective laser melting direct microstructure manipulation is feasible through adjustment of thermal gradients and solidification velocity. Currently, the exposure strategy and laser energy have to be adapted in order to meet a processing window suited for introducing highly anisotropic microstructures. As selective laser melting allows for production of filigree complex structures, the impact of geometry on the microstructure evolution is investigated in the current study and it is shown that miniaturization of structures as well leads to the evolution of anisotropic microstructure.

CYCLIC DEFORMATION BEHAVIOR OF AGED FeNiCoAlTa SINGLE CRYSTALS

The cyclic deformation behavior of [001] oriented Fe-28Ni-17Co-11.5Al-2.5Ta (at.%) shape memory single crystals was investigated under tension. Dog-bone shaped specimens were tested up to 100 cycles after different aging heat treatments in order to characterize the cyclic stress–strain response and functional degradation. The smaller particles formed as a consequence of short aging for 1 h at 700°C, as compared to longer aging for 7 h, resulted in significantly enhanced resistance to cyclic degradation.

Early detection of crack initiation sites in TiAl alloys during low-cycle fatigue at high temperatures utilizing digital image correlation

Abstract Fatigue-induced damage accumulation was investigated in a third generation titanium aluminide alloy both at room temperature and at a temperature of 700 °C promoting oxidation. The digital image correlation technique was utilized for monitoring the evolution of local strain fields with cyclic deformation at both temperatures. With the aid of a newly adopted surface patterning technique, digital image correlation successfully detected the crack initiation sites prior to the actual formation of the cracks. Despite the oxidation at elevated temperatures, digital image correlation could detect the crack initiation sites at the early stages of the cyclic deformation, laying out the potential of this technique for monitoring the damage evolution in various metallic materials under severe service conditions.

Processing of New Materials by Additive Manufacturing: Iron-Based Alloys Containing Silver for Biomedical Applications

In the biomedical sector, production of bioresorbable implants remains challenging due to improper dissolution rates or deficient strength of many candidate alloys. Promising materials for overcoming the prevalent drawbacks are iron-based alloys containing silver. However, due to immiscibility of iron and silver these alloys cannot be manufactured based on conventional processing routes. In this study, iron-manganese-silver alloys were for the first time synthesized by means of additive manufacturing. Based on combined mechanical, microscopic, and electrochemical studies, it is shown that silver particles well distributed in the matrix can be obtained, leading to cathodic sites in the composite material. Eventually, this results in an increased dissolution rate of the alloy. Stress–strain curves showed that the incorporation of silver barely affects the mechanical properties.