SSAM Spring Final Presentation

Solid-State Additive Manufacturing

Jordan Boston

Joshua Shaver

Jonnie Weiandt

Ty Helgeson

Donny Donham

David Lindberg

Wayne Gilley

Peter Barber

Nick Liffrig

28 April 2016

Solid-State Project Scope

Create a Functionally Gradient Transition from SAE 4130 to Alloy 690• Model and compare to results from created transition piece

• Analyze hardness across the transition

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Functionally Gradient Materials• Smooth Transition in properties

• Decreases Carbon Diffusion

• Decrease Intermetallics

• Reduce Residual Stresses from the Coefficient of Thermal Expansion mismatch

Traditional Transition:A to B Instantaneously

Additively Manufactured Transition:A to B Gradually

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What is Additive Manufacturing?• Process in which you create real objects from 3D model data by

joining materials layer by layer• Traditional manufacturing methods use subtractive manufacturing methods

• Create complex geometries that are impossible to create with traditional manufacturing methods as well as embed sensors during manufacturing

• Able to vary the composition of each layer

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Two Approaches

Solid-State Welding

• No melting

• No dilution

• High startup cost

Fusion Welding

• Melting and resolidification

• Dilution during welding

• Low startup cost

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Initial Research

• MIG/TIG Brazing

• High frequency induction welding

• Ultrasonic welding

• Friction Stir Welding (FSW)• Consumable tool

• Powder feed system

• Sandwich configuration

Sandwich configuration

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Consumable Tool

• Proof of concept • Aluminum surfacing

• Brass surfacing

• What We Learned• Determined process was not desirable to pursue for steel

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POWDER FEED SYSTEM

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POWDER FEED SYSTEM

• Commercial Powder Feeders

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Sandwich configuration

Sandwich Configuration - 5 Step1. Determine FSW tool geometry

2. Verify the model with the thermal camera

3. Optimize parameters for each layera) Open air welds

b) Submerged welds

4. Create final weld

5. Conduct testing on final welda) Examine microstructure

b) Survey hardness

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1. Tool Geometry

• Tungsten Rhenium Tool• Expensive

• Very Brittle

• Difficult to machine

• Tapered Cylindrical Geometry

• 5.6mm Pin Length

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Tapered Cylindrical

2. Verify Model

• Model – 1150°C

• Actual – 1100°C

°C

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3. Optimize Parameters – FSW In Air • Initial Parameters

• Spindle Speed – 1,015 RPM

• Travel Speed – 4.04 ipm

• Downforce – 1,000lbs

• Tool Angle – 0°

2 Layers of 410

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3. Optimize Parameters – FSW In Air• Final Parameters

• Spindle Speed – 815 RPM

• Travel Speed – 2.96 ipm

• Downforce – ~6,000lbs


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Layer of 410

Layers of 304

FSW Underwater• Came across this process while researching shielding

Benefits:

• Extend tool life

• Water acts as shielding for the weld

• Increases the mechanical properties of the weld

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Underwater Test Welds

FSW In Air

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3. Optimize Parameters – FSW Underwater

• Initial Parameters• Spindle Speed – 815 RPM

• Travel Speed – 2.96 in/min

• Downforce –6,000lbs


• Cold Water – 25°C

2 Layers of 304

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3. Optimize Parameters – FSW Underwater• Final Parameters

• Spindle Speed – 428RPM & 815RPM for the last layer

• Travel Speed – 2.96in/min

• Downforce – varied with each layer of the sandwich


• Hot Water – 50°C

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4. Final Weld • 4130 to 410


4130 at 50x 410 at 200xFinal Weld Macro

4130

410

304

310

690

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690 at 500x 690 at 200xFinal Weld Macro

4130

410

304

310

690

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Modeling Diffusion

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• Functionally Graded Transition between 4130 and 690

• Temp = 1000°C

• Time = 24 hrs

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Modeling Diffusion

• 5-Step transition between 4130 and 690

• Temp = 1000°C

• Time = 24 hrs

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150

175

200

225

250

275

300

0 10 20 30 40 50 60 70 80 90 100 110

Har

dn

ess

(HV

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)Hardness

Hardness (Solid State) Linear (Hardness (Solid State))

4130

410

304

310

690

Compare to Fusion Welding Team

• Time Required

• Hardness Values

• Scalability

• Geometry

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Conclusions & Future Work

• A successful sandwich transition was created

• Verify the Carbon Diffusion Model

• Further research on Underwater FSW should be looked into

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Donors

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Questions?

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Solid-State Additive Manufacturing

Jordan Boston

Joshua Shaver

Jonnie Weiandt

Ty Helgeson

Donny Donham

David Lindberg

Wayne Gilley

Peter Barber

Nick Liffrig

Backup Slides

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POWDER FEED SYSTEM

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410 (pin) at 500x 304 (pin) at 50xFinal Weld Macro

4130

410

304

310

690

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310 (pin) at 500x 310 (far right of pin) at 200xFinal Weld Macro

4130

410

304

310

690

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SSAM Spring Final Presentation

Documents

Transcript of SSAM Spring Final Presentation