<p>Proper thermal management in arc additive manufacturing (Arc-AM) should avoid heat accumulation and hence related metallurgical issues in the parts being built as well as concurrently accomplish adequate near net shaping with reduced production times. In the specific case of super duplex stainless steels (SDSS), the cooling rates of the parts must be watched closely so that nearly equal amounts of ferrite (δ) and austenite (γ) without deleterious phases, such as sigma (σ) and chi (χ), are preferably formed for appropriate corrosion and mechanical performances. Whereas natural cooling (NC), usually with long waiting times between the successive layers, is the most common method employed to achieve such goals as for other metals, the general objective of this work was to assess a different thermal management strategy for building SDSS parts via Arc-AM, prospectively more productive, called near-immersion active cooling (NIAC). For this purpose, thin walls of similar size were built from an AWS ER2594 wire via the gas metal arc (GMA) AM process set to operate in the CMT and Pulsed modes with different travel speeds and under the NIAC technique with fixed dwell times as well as under the NC solution (taken as comparison basis) with fixed interlayer temperature and dwell time as thermal management strategies. Such parts were specifically assessed in the as-built state in terms of geometrical characteristics, presence of voids, δ/γ balance, formation of secondary phases, and production time. With the NIAC technique, both with dwell times of 30 and 15 s, it was possible to produce forms with stable cross section as with NC with interlayer temperature of 100 °C and consequent increasing dwell times and in contrast to the use of NC with dwell time of 30 s, regardless of the deposition setting (operational mode and TS level) employed. Also, with the NIAC technique, as for all the NC cases, there was no evidence that voids of any kind were induced by its more effective cooling capability. Moreover, the rapid cooling action provided by the NIAC technique, especially in combination with 30 s of dwell time, favored δ/γ balances always closer to 50% (so quite acceptable), being slightly more appropriate than NC with interlayer temperature of 100 °C and yet much more adequate than NC with dwell time of 30 s, whose application particularly resulted in substantially lesser δ formation due to heat accumulation. Though possibly tolerable, secondary austenite (γ2) colonies were found under all thermal management strategies, except for the cases of NC with interlayer temperature of 100 °C. Under NC with dwell time of 30 s there was also evidence of σ and χ formation, which was not the case with the NIAC application and with NC with interlayer temperature of 100 °C. When operating with the Pulsed mode, the worst thermal scenario evaluated, the idle portion of time (without material deposition), more relevant to the production time than the active portion (with material deposition), totalized only 6 min with the application of the NIAC technique and dwell time of 15 s, whereas it reached 190 min with the conventional solution of NC and interlayer temperature of 100 °C for the same target wall height. Thus, the possibility of applying the NIAC technique in Arc-AM of SDSS parts was demonstrated with significant gains in time-based productivity and without any major issue concerning phase balance and adequacy as well as in terms of geometrical and density quality in the as-built state.</p>

错误:搜索内容不能为空,请输入英文关键词
错误:关键词超出字数限制,请精简
高级检索

Application of near-immersion active cooling for thermal management in arc additive manufacturing of thin super duplex stainless steel walls

  • Vinicius Lemes Jorge,
  • Fernando Matos Scotti,
  • Felipe Ribeiro Teixeira,
  • Louriel Oliveira Vilarinho,
  • Ruham Pablo Reis

摘要

Proper thermal management in arc additive manufacturing (Arc-AM) should avoid heat accumulation and hence related metallurgical issues in the parts being built as well as concurrently accomplish adequate near net shaping with reduced production times. In the specific case of super duplex stainless steels (SDSS), the cooling rates of the parts must be watched closely so that nearly equal amounts of ferrite (δ) and austenite (γ) without deleterious phases, such as sigma (σ) and chi (χ), are preferably formed for appropriate corrosion and mechanical performances. Whereas natural cooling (NC), usually with long waiting times between the successive layers, is the most common method employed to achieve such goals as for other metals, the general objective of this work was to assess a different thermal management strategy for building SDSS parts via Arc-AM, prospectively more productive, called near-immersion active cooling (NIAC). For this purpose, thin walls of similar size were built from an AWS ER2594 wire via the gas metal arc (GMA) AM process set to operate in the CMT and Pulsed modes with different travel speeds and under the NIAC technique with fixed dwell times as well as under the NC solution (taken as comparison basis) with fixed interlayer temperature and dwell time as thermal management strategies. Such parts were specifically assessed in the as-built state in terms of geometrical characteristics, presence of voids, δ/γ balance, formation of secondary phases, and production time. With the NIAC technique, both with dwell times of 30 and 15 s, it was possible to produce forms with stable cross section as with NC with interlayer temperature of 100 °C and consequent increasing dwell times and in contrast to the use of NC with dwell time of 30 s, regardless of the deposition setting (operational mode and TS level) employed. Also, with the NIAC technique, as for all the NC cases, there was no evidence that voids of any kind were induced by its more effective cooling capability. Moreover, the rapid cooling action provided by the NIAC technique, especially in combination with 30 s of dwell time, favored δ/γ balances always closer to 50% (so quite acceptable), being slightly more appropriate than NC with interlayer temperature of 100 °C and yet much more adequate than NC with dwell time of 30 s, whose application particularly resulted in substantially lesser δ formation due to heat accumulation. Though possibly tolerable, secondary austenite (γ2) colonies were found under all thermal management strategies, except for the cases of NC with interlayer temperature of 100 °C. Under NC with dwell time of 30 s there was also evidence of σ and χ formation, which was not the case with the NIAC application and with NC with interlayer temperature of 100 °C. When operating with the Pulsed mode, the worst thermal scenario evaluated, the idle portion of time (without material deposition), more relevant to the production time than the active portion (with material deposition), totalized only 6 min with the application of the NIAC technique and dwell time of 15 s, whereas it reached 190 min with the conventional solution of NC and interlayer temperature of 100 °C for the same target wall height. Thus, the possibility of applying the NIAC technique in Arc-AM of SDSS parts was demonstrated with significant gains in time-based productivity and without any major issue concerning phase balance and adequacy as well as in terms of geometrical and density quality in the as-built state.