Abstract
Hot-isostatic pressing has been applied to Zirconium plate fabricated using the ultrasonic additive manufacturing (UAM) technique to enhance interfacial bond quality. Specimens heated to 800 C for 1 h at 100 MPa pressure showed grain growth across many prior foil-to-foil interfaces, thereby increasing foil adhesion. In addition to the material softening induced by a loss of Hall-Petch strengthening, premature failure of specimens loaded parallel to the build direction was observed. Premature specimen failure was attributed to the local delamination at prior foil-to-foil boundaries where grain growth was pinned by Ti impurities introduced during the UAM process via the interaction between a Ti-alloy buffer foil and the welded Zr-foils underneath. In addition, the presence of Ti along select foil interfaces resulted in the nucleation and growth of secondary (Zr,Ti)(Fe,Cr) laves phases during higher-temperature thermomechanical processing. Using a combination of micro-scale X-ray computed tomography, fractography, and in-situ digital image correlation, the effect of defects along prior foil-to-foil boundaries was revealed as delamination-assisted plasticity accelerated specimen failure in preferred tensile orientations. These findings underscore the importance of impurity control when optimizing weld quality of higher-strength material systems using ultrasonic welding.
| Original language | English |
|---|---|
| Article number | 103110 |
| Journal | Additive Manufacturing |
| Volume | 59 |
| DOIs | |
| State | Published - Nov 2022 |
Funding
This manuscript has been authored by UT-Battelle, LLC, under Contract No. DE-AC05–00OR22725 with the U.S. Department of Energy and is based upon work supported by the U.S. Department of Energy, National Nuclear Security Administration, Office of Defense Nuclear Nonproliferation Research and Development (DNN R&D). The authors would like to acknowledge the aid of Adam Hehr and Mark Norfolk at Fabrisonic LLC in Columbus, OH for their assistance with the UAM builds. The authors are also grateful for the support of Tom Geer and Victoria Cox for the extensive metallography work associated with this project. The work of Randy Parten and Doug Stringfield on miniature specimen machining is also much appreciated. Additionally, the authors appreciate the support of ATI Specialty Alloys and Components in Albany, OR. Notice: This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05–00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ).
| Funders | Funder number |
|---|---|
| Adam Hehr and Mark Norfolk at Fabrisonic LLC | |
| DNN R&D | |
| Office of Defense Nuclear Nonproliferation Research and Development | |
| U.S. Department of Energy | |
| National Nuclear Security Administration | |
| Allegheny Technologies Incorporated | |
| Universidad Autónoma de Madrid |
Keywords
- Electron backscatter diffraction (EBSD)
- Grain growth
- Hot isostatic pressing
- Tensile test
- Ultrasonic additive manufacturing
- X-ray tomography
- Zirconium
