Session: 02-11-02: Session #2: Laser-Based Advanced Manufacturing and Materials Processing

Paper Number: 88299

88299 - Characterization of Additively Manufactured Metals from ADDERE Printing 

Midwest Engineered Systems Inc. has created a novel laser wire metal deposition process, ADDERE manufacturing. ADDERE has a much higher deposition rate than powder bed fusion, making it ideal for large components. In this project, the mechanical properties of ADDERE printed materials were tested and compared to typical values found in ASM publications show the quality of materials manufactured by the ADDERE printing process. This testing was done for Ti-6Al-4V and 17-4 PH Stainless Steel. For 17-4 PH, the samples were printed in a cross hatched pattern, and the testing results were compared to existing data from single direction samples that were tested in previous research. The Ti-6Al-4V was cut into samples using a water jet cutter and machined into tensile bars at Perkins Engineering. The tensile testing was conducted at MSOE, and the Rockwell Hardness, Vickers Microhardness, and Optical Microscopy were conducted at INNIO Waukesha Gas Engine systems. The Ti-6Al-4V sample met the expected values in the ASM literature, and the cross hatched 17-4 PH had a higher hardness and better microstructure than the single direction samples from the previous research. When Ti64 samples were manufactured in the cross hatched pattern, properties indicated slight improvement and more homogeneity than those printed in single layer direction. ADDERE’s printing process is producing materials that are compatible with their expected uses. This work showcases an excellent industry collaboration of an undergraduate research experience.

The results of this research indicated excellent compliance with ASM standards for the ADDERE printed Ti-6Al-4V and 17-4 PH Stainless Steel. Also, the quality of the microstructure reflects well on the ADDERE printing process. The clarity of the microstructure is due the control over the laser power and the melt pool in the printing process. MWES has optimized the process to make sure that the laser power is not only enough to melt the top layer, but also penetrates a few layers down, which creates a homogeneous melt pool, allowing to microstructure to also be homogenous, without any indication of the print layers. Another notable result is that the cross hatched direction outperformed the single direction samples in both hardness and microstructure. With 17-4 PH results, it must be reiterated that the difference in microstructure is more due to the print atmosphere. The single direction sample was printed with an argon shield gas, which still allowed some porosity to develop. The cross hatched sample was printed with a fully inert argon atmosphere with 500-1000 PPM O2, and produced a clear, martensitic microstructure with little to no porosity. The cost of maintaining an inert chamber must be taken into consideration when designing for additive manufacturing of various metal blocks.

MWES continues to work with MSOE on characterization studies of materials. This work also brought other industries (Perkins Engineering and Innio Waukesha Gas Engines and its principal scientists) to contribute intellectually and to provide critical facilities for successful completion of the project. This collaboration is proving to be a good model for implementing REU and other research projects.

Presenting Author: Subha Kumpaty Milwaukee School Of Engrg

Presenting Author Biography: Dr. Subha Kumpaty teaches at Milwaukee School of Engineering and leads National Science Foundation sponsored Research Experiences for Undergraduates. He is also director of the Master of Science in Engineering program.

Authors:

Joshua Foster University of Memphis
Subha Kumpaty Milwaukee School Of Engrg
Liam Coen INNIO Waukesha Engines
Al Perkins Perkins Engineering
Michael Gengler Midwest Engineered Systems
Scott Woida Midwest Engineered Systems