No CrossRef data available.
Article contents
Effect of oxygen shielding on the tensile and fatigue performance of 300M repaired through laser-directed energy deposition
Published online by Cambridge University Press: 03 November 2023
Abstract
Laser-directed energy deposition (L-DED) is a key enabling technology for the repair of high-value aerospace components, as damaged regions can be removed and replaced with additively deposited material. While L-DED repair improves strength and fatigue performance compared to conventional subtractive techniques, mechanical performance can be limited by process-related defects. To assess the role of oxygen on defect formation, local and chamber-based shielding methods were applied in the repair of 300M high strength steel. Oxidation between layers for locally shielded specimens is confirmed to cause large gas pores which have deleterious effects on fatigue life. Such pores are eliminated for chamber shielded specimens, resulting in an increased ductility of ∼15%, compared to ∼11% with chamber shielding. Despite this, unmelted powder defects are not affected by oxygen content and are found in both chamber- and locally shielded samples, which still have negative consequences for fatigue.
- Type
- Research Article
- Information
- The Aeronautical Journal , Volume 127 , Special Issue 1318: AIAC 2023 , December 2023 , pp. 2118 - 2124
- Copyright
- © The Author(s), 2023. Published by Cambridge University Press on behalf of Royal Aeronautical Society
Footnotes
A version of this paper first appeared at The Australian International Aerospace Congress 2021 (AIAC19).
References
Liu, R., Wang, Z., Sparks, T., Liou, F. and Newkirk, J. 13 - Aerospace applications of laser additive manufacturing, in Laser Additive Manufacturing, Brandt, M., Ed, Woodhead Publishing, 2017, pp 351–371.CrossRefGoogle Scholar
Kundu, S., Jones, R., Peng, D., Matthews, N., Alankar, A., Raman, S.R. and Huang, P. Review of requirements for the durability and damage tolerance certification of additively manufactured aircraft structural parts and AM repairs, Materials, 2020, 13, (6), p 1341.CrossRefGoogle ScholarPubMed
Kanishka, K. and Acherjee, B. A systematic review of additive manufacturing-based remanufacturing techniques for component repair and restoration, J. Manuf. Processes, 2023, 89, pp 220–283.CrossRefGoogle Scholar
Nowotny, S., Scharek, S., Beyer, E. and Richter, K.-H. Laser beam build-up welding: precision in repair, surface cladding, and direct 3D metal deposition, J. Therm. Spray Technol., 2007, 16, pp 344–348.CrossRefGoogle Scholar
Kelbassa, I., Gasser, A. and Wissenbach, K. Laser cladding as a repair technique for BLISKs out of titanium and nickel base alloys used in aero engines, Pacific International Conference on Applications of Lasers and Optics, Laser Institute of America, 2004.CrossRefGoogle Scholar
Richter, K.-H., Orban, S. and Nowotny, S. Laser cladding of the titanium alloy Ti6242 to restore damaged blades, Proceedings of the 23rd International Congress on Applications of Lasers and Electro-optics, 2004.CrossRefGoogle Scholar
Choi, Y.R., Sun, S.D., Liu, Q., Brandt, M. and Qian, M. Influence of deposition strategy on the microstructure and fatigue properties of laser metal deposited Ti-6Al-4V powder on Ti-6Al-4V substrate, Int. J. Fatigue, 2020, 130, p 105236.CrossRefGoogle Scholar
Chaurasia, J.K., Jinoop, A., Paul, C., Bindra, K., Balla, V.K. and Bontha, S. Effect of deposition strategy and post processing on microstructure and mechanical properties of serviced Inconel 625 parts repaired using laser directed energy deposition, Opt. Laser Technol., 2024, 168, p 109831.CrossRefGoogle Scholar
Chen, H., Lu, Y., Luo, D., Lai, J. and Liu, D. Epitaxial laser deposition of single crystal Ni-based superalloys: Repair of complex geometry, J. Mater. Process. Technol., 2020, 285, p 116782.CrossRefGoogle Scholar
Liu, Z. and Qi, H. Effects of processing parameters on crystal growth and microstructure formation in laser powder deposition of single-crystal superalloy, J. Mater. Process. Technol., 2015, 216, pp 19–27.CrossRefGoogle Scholar
Da Sun, S., Liu, Q., Brandt, M., Luzin, V., Cottam, R., Janardhana, M. and Clark, G. Effect of laser clad repair on the fatigue behaviour of ultra-high strength AISI 4340 steel, Mater. Sci. Eng. A, 2014, 606, pp 46–57.CrossRefGoogle Scholar
Da Sun, S., Fabijanic, D., Barr, C., Liu, Q., Walker, K., Matthews, N., Orchowski, N., Easton, M. and Brandt, M. In-situ quench and tempering for microstructure control and enhanced mechanical properties of laser cladded AISI 420 stainless steel powder on 300M steel substrates, Surface Coat. Technol., 2018, 333, pp 210–219.CrossRefGoogle Scholar
Lourenço, J.M., Da Sun, S., Sharp, K., Luzin, V., Klein, A.N., Wang, C.H. and Brandt, M. Fatigue and fracture behavior of laser clad repair of AerMet
${}^{\circledR}$
100 ultra-high strength steel, Int. J. Fatigue, 2016, 85, pp 18–30.CrossRefGoogle Scholar
${}^{\circledR}$
100 ultra-high strength steel, Int. J. Fatigue, 2016, 85, pp 18–30.CrossRefGoogle ScholarWalker, K., Lourenço, J., Sun, S., Brandt, M. and Wang, C. Quantitative fractography and modelling of fatigue crack propagation in high strength AerMet
${}^{\circledR}$
100 steel repaired with a laser cladding process, Int. J. Fatigue, 2017, 94, pp 288–301.CrossRefGoogle Scholar
${}^{\circledR}$
100 steel repaired with a laser cladding process, Int. J. Fatigue, 2017, 94, pp 288–301.CrossRefGoogle ScholarBarr, C., Da Sun, S., Easton, M., Orchowski, N., Matthews, N. and Brandt, M. Influence of delay strategies and residual heat on in-situ tempering in the laser metal deposition of 300M high strength steel, Surface Coat. Technol., 2020, 383, p 125279.CrossRefGoogle Scholar
Barr, C., Rashid, R.A.R., Da Sun, S., Easton, M., Palanisamy, S., Orchowski, N., Matthews, N., Walker, K. and Brandt, M. Role of deposition strategy and fill depth on the tensile and fatigue performance of 300M repaired through laser directed energy deposition, Int. J. Fatigue, 2021, 146, p 106135.CrossRefGoogle Scholar
Zhong, C., Gasser, A., Schopphoven, T. and Poprawe, R. Experimental study of porosity reduction in high deposition-rate Laser Material Deposition, Opt. Laser Technol., 2015, 75, pp 87–92.CrossRefGoogle Scholar
Ahsan, M.N., Bradley, R. and Pinkerton, A.J. Microcomputed tomography analysis of intralayer porosity generation in laser direct metal deposition and its causes, J. Laser Appl., 2011, 23, (2), p 022009.CrossRefGoogle Scholar
Svetlizky, D., Zheng, B., Buta, T., Zhou, Y., Golan, O., Breiman, U., Haj-Ali, R., Schoenung, J.M., Lavernia, E.J. and Eliaz, N. Directed energy deposition of Al 5xxx alloy using Laser Engineered Net Shaping (LENS
${}^{\circledR}$
), Mater. Des., 2020, 192, p 108763.CrossRefGoogle Scholar
${}^{\circledR}$
), Mater. Des., 2020, 192, p 108763.CrossRefGoogle ScholarDong, Z., Kang, H., Xie, Y., Chi, C. and Peng, X. Effect of powder oxygen content on microstructure and mechanical properties of a laser additively-manufactured 12CrNi2 alloy steel, Mater. Lett., 2019, 236, pp 214–217.CrossRefGoogle Scholar
Chouhan, A., Aggarwal, A. and Kumar, A. A computational study of porosity formation mechanism, flow characteristics and solidification microstructure in the L-DED process, Appl. Phys. A, 2020, 126, (11), pp 1–12.CrossRefGoogle Scholar
Jing, G., Huang, W., Yang, H. and Wang, Z. Microstructural evolution and mechanical properties of 300M steel produced by low and high power selective laser melting, J. Mater. Sci. Technol., 2020, 48, pp 44–56.CrossRefGoogle Scholar
Sanaei, N. and Fatemi, A. Defects in additive manufactured metals and their effect on fatigue performance: a state-of-the-art review, Prog. Mater. Sci., 2020, p 100724.Google Scholar