Additively Manufacturing Nitinol Shape Memory Alloys for Advanced Actuator Designs

The objective of this research was to understand the role of feedstock production in the phase transformation behavior of additively manufactured Ni-Ti alloys for advanced actuator design. Industrial adoption of additively manufactured Ni-Ti alloys depends on the ability to produce repeatable phase transformation behavior, quantified here by the austenite to martensite transformation on heating. Small variations in the alloy composition may have a significant effect on the temperature at which this transformation occurs. This project showed that the powder characteristics play an important role in determining this behavior. Increases in the surface area per unit volume of the powder, either as a function of size distribution or morphology, have the effect of reducing the Ti content in the alloy through the formation of Ti-rich oxides on the powder surface, which has the effect of depressing the transformation temperature. Preferential Ni vaporization during additive manufacturing can partially offset this effect. To achieve repeatable results, it is important to understand the effect of powder oxidation, and to control the powder characteristics.