Additive manufacturing as a processing route for steel-aluminum bimetallic structures

Rangasayee Kannan; Yousub Lee; Dean Pierce; Kinga Unocic; Blane Fillingim; Thomas Feldhausen; Andres Marquez Rossy; Hsin Wang; Peeyush Nandwana

doi:10.1016/j.matdes.2023.112003

Additive manufacturing as a processing route for steel-aluminum bimetallic structures

Rangasayee Kannan, Yousub Lee, Dean Pierce, Kinga Unocic, Blane Fillingim, Thomas Feldhausen, Andres Marquez Rossy, Hsin Wang, Peeyush Nandwana

Research output: Contribution to journal › Article › peer-review

12 Scopus citations

Abstract

Here we present results on the fabrication of steel-aluminum bi-metallic structures using directed energy deposition additive manufacturing. The challenges associated with the fabrication of a sharp transition from steel to aluminum are uncovered using ex-situ characterization techniques and thermo-mechanical modeling of the deposition process. It was found that the fabrication of a sharp steel-aluminum transition is challenging with extensive cracking observed at the interface. The cracking was attributed to the combined effect of residual stress development due to thermal expansion coefficient mismatch and the presence of ordered intermetallics with low ductility at the interface. Using a coupled thermodynamic and thermo-mechanical modeling approach, potential pathways to enable the fabrication of steel-aluminum bi-metallic structures using additive manufacturing are proposed. The results presented here can lay the foundation for future work on the fabrication of bi-metallic steel-aluminum structures using directed energy deposition.

Original language	English
Article number	112003
Journal	Materials and Design
Volume	231
DOIs	https://doi.org/10.1016/j.matdes.2023.112003
State	Published - Jul 2023

Funding

This research is sponsored by the Laboratory Directed Research and Development Program of Oak Ridge National Laboratory, managed by UT-Battelle, LLC, for the US Department of Energy. Research was performed at the U.S. Department of Energy’s Manufacturing Demonstration Facility, located at Oak Ridge National Laboratory. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The authors acknowledge Dustin Heidel and Ian Stinson for arc melting and machining, Sarah Graham for metallographic sample preparation, and Brian Jordan and Dennis Brown for inputs on DED printing. This research is sponsored by the Laboratory Directed Research and Development Program of Oak Ridge National Laboratory, managed by UT-Battelle, LLC, for the US Department of Energy. Research was performed at the U.S. Department of Energy's Manufacturing Demonstration Facility, located at Oak Ridge National Laboratory. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The authors acknowledge Dustin Heidel and Ian Stinson for arc melting and machining, Sarah Graham for metallographic sample preparation, and Brian Jordan and Dennis Brown for inputs on DED printing.

Keywords

Aluminum
Bimetallic structures
Directed energy deposition
Hybrid materials
Steel

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.matdes.2023.112003

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title = "Additive manufacturing as a processing route for steel-aluminum bimetallic structures",

abstract = "Here we present results on the fabrication of steel-aluminum bi-metallic structures using directed energy deposition additive manufacturing. The challenges associated with the fabrication of a sharp transition from steel to aluminum are uncovered using ex-situ characterization techniques and thermo-mechanical modeling of the deposition process. It was found that the fabrication of a sharp steel-aluminum transition is challenging with extensive cracking observed at the interface. The cracking was attributed to the combined effect of residual stress development due to thermal expansion coefficient mismatch and the presence of ordered intermetallics with low ductility at the interface. Using a coupled thermodynamic and thermo-mechanical modeling approach, potential pathways to enable the fabrication of steel-aluminum bi-metallic structures using additive manufacturing are proposed. The results presented here can lay the foundation for future work on the fabrication of bi-metallic steel-aluminum structures using directed energy deposition.",

keywords = "Aluminum, Bimetallic structures, Directed energy deposition, Hybrid materials, Steel",

author = "Rangasayee Kannan and Yousub Lee and Dean Pierce and Kinga Unocic and Blane Fillingim and Thomas Feldhausen and Rossy, {Andres Marquez} and Hsin Wang and Peeyush Nandwana",

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AU - Kannan, Rangasayee

AU - Lee, Yousub

AU - Pierce, Dean

AU - Unocic, Kinga

AU - Fillingim, Blane

AU - Feldhausen, Thomas

AU - Rossy, Andres Marquez

AU - Wang, Hsin

AU - Nandwana, Peeyush

PY - 2023/7

Y1 - 2023/7

N2 - Here we present results on the fabrication of steel-aluminum bi-metallic structures using directed energy deposition additive manufacturing. The challenges associated with the fabrication of a sharp transition from steel to aluminum are uncovered using ex-situ characterization techniques and thermo-mechanical modeling of the deposition process. It was found that the fabrication of a sharp steel-aluminum transition is challenging with extensive cracking observed at the interface. The cracking was attributed to the combined effect of residual stress development due to thermal expansion coefficient mismatch and the presence of ordered intermetallics with low ductility at the interface. Using a coupled thermodynamic and thermo-mechanical modeling approach, potential pathways to enable the fabrication of steel-aluminum bi-metallic structures using additive manufacturing are proposed. The results presented here can lay the foundation for future work on the fabrication of bi-metallic steel-aluminum structures using directed energy deposition.

AB - Here we present results on the fabrication of steel-aluminum bi-metallic structures using directed energy deposition additive manufacturing. The challenges associated with the fabrication of a sharp transition from steel to aluminum are uncovered using ex-situ characterization techniques and thermo-mechanical modeling of the deposition process. It was found that the fabrication of a sharp steel-aluminum transition is challenging with extensive cracking observed at the interface. The cracking was attributed to the combined effect of residual stress development due to thermal expansion coefficient mismatch and the presence of ordered intermetallics with low ductility at the interface. Using a coupled thermodynamic and thermo-mechanical modeling approach, potential pathways to enable the fabrication of steel-aluminum bi-metallic structures using additive manufacturing are proposed. The results presented here can lay the foundation for future work on the fabrication of bi-metallic steel-aluminum structures using directed energy deposition.

KW - Aluminum

KW - Bimetallic structures

KW - Directed energy deposition

KW - Hybrid materials

KW - Steel

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M1 - 112003

ER -

Additive manufacturing as a processing route for steel-aluminum bimetallic structures

Abstract

Funding

Keywords

UN SDGs

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