Effect of Process Parameters on Deposition Properties of Functionally Graded STS 316/Fe Manufactured by Laser Direct Metal Deposition
Abstract
:1. Introduction
2. Experimental Procedures
3. Results and Discussion
3.1. Effect of Process Parameters on the Bead Geometry
3.1.1. Contact Tip to Work-Piece Distance
3.1.2. Beam Shift
3.1.3. Laser Power
3.1.4. Flow Rate
3.1.5. Travel Speed
3.2. Additive Manufacturing
4. Conclusions
- The process conditions for producing sound beads without humping beads, pores, and lack of fusion were derived using Fe powder with uneven size and shape.
- The shape of the bead and the size of the pore were affected by the change of CTWD. The beam shift parameter had the effect of changing the angle of the bead, and the laser power was effective in changing the aspect ratio of the bead.
- Low flow rates caused puckering, while excessive flow rates reduced material efficiency. In addition, humping beads were observed at slow travel speed and many pores due to rapid solidification at high travel speed.
- The FGM samples showed gradual changes in composition and phase along the layers. In XRD analysis, any intermetallic compounds such as sigma phase was not detected.
- When the STS316 was directly deposited on the mild steel, there were many pores and cracks at the interface. However, when the FGM was produced by using Fe and STS316 powder, defects occurring at the interface of the first layer could be removed.
- However, as the Fe powder was mixed with STS316 powder, pores were observed between the interfaces, which resulted in the presence of chrome oxide at the interface.
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Powder | Fe | C | O | Si | Mn | P | S | Ni | Cr | Mo |
---|---|---|---|---|---|---|---|---|---|---|
STS316 | Bal. | 0.02 | 0.03 | 0.01 | 1.06 | 0.005 | 0.003 | 12.00 | 17.00 | 2.04 |
Fe | Bal. | 0.01 | 0.15 | 0.08 | 0.13 | 0.008 | 0.006 | 0.005 | 0.005 | 0.003 |
Process Parameter | Single Pass | Build Production |
---|---|---|
Laser Power (kW) | 0.5–2.5 [2] | 2 |
Travel speed (m/s) | 0.001–0.01 [0.005] | 0.0083 |
Flow rate (g/min) | 15–30 [20] | 30 |
Beam Shift (mm) | 0–2 [0] | 0 |
Contact tip to work-piece distance (mm) | 5–15 [10] | 10–11 |
Shielding gas (L/min) | 15 (Ar) | 15 (Ar) |
Carrier gas (L/min) | 10 (Ar) | 10 (Ar) |
Sample | Sample 1 (Dissimilar Welding) | Sample 2 (Functionally Graded Materials) | |
---|---|---|---|
Composition (wt %) | Composition (wt %) | Layer Name | |
5th layer | STS316 | 100% STS316 | 0Fe |
4th layer | STS316 | 75% STS316 + 25% Fe | 25Fe |
3rd layer | STS316 | 50% STS316 + 50% Fe | 50Fe |
2nd layer | STS316 | 75% STS316 + 25% Fe | 75Fe |
1st layer | STS316 | 100% Fe | 100Fe |
Substrate | Mild steel | Mild steel |
Sieve Number | Particle Size (μm) | Distribution (wt %) * | |
---|---|---|---|
Fe | STS316 | ||
100 | >150 | 2 | - |
140 | 105–150 | 18 | 99 |
200 | 74–105 | 29 | |
325 | 44–74 | 30 | |
−325 | <44 | 21 | 1 |
Process Parameter | CTWD (mm) | Beam Shift (mm) | Laser Power (kW) | Flow Rate (g/min) | Travel Speed (cm/s) |
---|---|---|---|---|---|
Value | 10–13 | 0–0.5 | 1.5–2 | 20–30 | 0.5–0.9 |
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Nam, S.; Cho, H.; Kim, C.; Kim, Y.-M. Effect of Process Parameters on Deposition Properties of Functionally Graded STS 316/Fe Manufactured by Laser Direct Metal Deposition. Metals 2018, 8, 607. https://doi.org/10.3390/met8080607
Nam S, Cho H, Kim C, Kim Y-M. Effect of Process Parameters on Deposition Properties of Functionally Graded STS 316/Fe Manufactured by Laser Direct Metal Deposition. Metals. 2018; 8(8):607. https://doi.org/10.3390/met8080607
Chicago/Turabian StyleNam, Sangwoo, Heewon Cho, Cheolhee Kim, and Young-Min Kim. 2018. "Effect of Process Parameters on Deposition Properties of Functionally Graded STS 316/Fe Manufactured by Laser Direct Metal Deposition" Metals 8, no. 8: 607. https://doi.org/10.3390/met8080607