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CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Joining of Dissimilar Materials/Addi4ve Manufacturing Thrust: Addi4ve
Manufacturing of Large Scale Metallic Components
S. S. Babu1, R. DeHoff2 and L. Love2 1The University of Tennessee, Knoxville 2Manufacturing Demonstra<on Facility,
Oak Ridge Na<onal Laboratory, Oak Ridge
CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Need and Industrial Relevance • Dissimilar materials are inherent part of
power genera4on applica4ons. • Transi4on joints are made by fusion
welding or cladding processes. • However, these joints/clads have shown
premature failure due to thermal excursions associated with modern prac4ces.
• Expensive/energy intens4ve powder metallurgy process is being considered as a solu4on.
• Can we develop alterna4ve process based on addi4ve manufacturing principles?
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CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Project Goals • Energy efficient, precision addi4ve
manufacturing of large scale polymer chassis was demonstrated for automo4ve applica4ons.
• Is it possible to leverage this technology for metallic transi4on joints?
• Specific Goal: Demonstrate the feasibility of designing and making large scale (> 10 cm) transi4on joints between ferri4c and stainless steels with minimal dilu4on and without deleterious microstructure.
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CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Project Objec4ves • Metallurgical Design: Develop and
demonstrate the grada4on strategy for transi4on joints between Cr-‐Mo low alloy steels and stainless steels.
• Geometric (Hybrid) Design: Develop strategy for planar or helical or checkerboard based on strain par44oning calcula4ons/measurements.
• Demonstrate the feasibility: Addi4ve manufacturing these joints using large area metal addi4ve manufacturing
• Measure the strain par44oning: Validate the hypothesis and transfer the technology.
4 SA
508 Steel
316L SS
Incone
l 82
CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Metallurgical Design
• Using computa4onal thermodynamic and kine4c tools (e.g. DicTra), evaluate the extend of cross-‐diffusion in the transi4on joints. (example: P91 and Stellite 21)
• Develop transi4on joints to straddle the 4e-‐lines of the phase diagram to minimize the cross-‐diffusion.
• Ensure that the transi4on regions do not undergo bridle martensi4c transforma4on.
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CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Geometric Design & Processing
• Make smaller geometry transi4on joints (planar, helical and checkerboard) using DM3D-‐POM system (variables: power and speed)
• Evaluate the strain par44oning using digital image correla4on and Gleeble® equipment.
• Evaluate the strain par44oning using X-‐ray or neutron beam lines (e.g. SNS-‐Vulcan).
• Finalize the design and deploy using the large scale metal AM process
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Ref: Xinghua et al (2013)
CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Expected Outcomes/Deliverables
• Year 1: – Develop metallurgical and geometric designs for
transi<on joints between low-‐alloy (e.g. 2.25Cr-‐1Mo) and stainless steel (e. g. 316L), planar, helical or checkerboard
– Produce small blocks using DM3D-‐POM system – Validate microstructure and strain par<<oning
using DIC and X-‐ray or Neutron scaVering
• Year 2: – Extend the geometric and metallurgical design to
large scale metal AM process under development at ORNL.
– Manufacture a large scale structure and evaluate the target microstructure and geometrical distribu<on
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Measurement of strain induced transforma4on Smith et al (2014)
measurements of phase distribu4on in transi4on joint aker service
CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Impact • If our hypothesis of large scale metal
AM with a-‐priori geometric and metallurgical design is proven to be effec4ve, we can make these joints based on a given applica4on.
• Design and manufacturing system can be extended to high-‐temperature (transi4on joints), wear applica4on (valves), as well as, stamping tools for tradi4onal manufacturing.
• The design tools can be transferred to commercial makers of such large scale AM solu4on providers.
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Lundin, 1982
Klueh and King, 1982
CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Project Dura4on & Budget • Year 1: $70K/year
– Evalua4on of Geometry (plate design( and Computa4onal Design for 316 to Cr-‐Mo steel transi4on joints
– 1 PhD Student & 1 undergraduate student – Experimental processing & Characteriza4on – Go/No Go review & Engage AM Equipment
Makers for expanding the project scope to complex geometry and different processes (laser, arc, cold spray and ultrasonic addi4ve manufacturing)
• Year 2, 3 and 4: $140K/year – 2 PhD Students and 2 undergraduates – Based on review expand the project scope to
complex geometry (pipe geometry) & processes (see above)
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ITW Miller XMT® 350 CC/CV inverter with a Controlled Short Circuit (CSC)
Lincoln Electric Laser-‐Wire Process
CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Synergy with other projects • Innova<ve Process Control Thrust -‐ Robo<cs for Large-‐
Scale Addi<ve Manufacturing, William Hamel (MABE) • Weldability and Life Extension Thrust – Applica<on of
Neutron ScaVering Tools to Characterize Strain Par<<oning in Dissimilar Welds – Hahn Choo (MSE)
• Addi<ve Manufacturing Thrust – Applica<on of Neutron ScaVering Tools for Verifica<on and Valida<on of Addi<ve Manufacturing –Andrew Payzant (ORNL), Lindsay Kolbus (ORNL), and Claudia Rawn (MSE)
• Integrated Process Modeling Thrust: Applica<ons of ICME tools for Welding and Joining – Adrian Sabu and Zhili Feng (MABE)
• Weldability and Life Extension Thrust – Welding Metallurgy of High Cr steels -‐ Carl Lundin (MSE)
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CIMJSEA
NSF-‐I/UCRC: Center for Integrative Materials Joining Science for Energy Applications
Ques4ons and comments
Email: [email protected]
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