Session: 04-20-01: Design of Engineered Materials and Components for Additive Manufacturing

Paper Number: 147094

147094 - Wire-Powder Laser Directed Energy Deposition of Inconel-Grcop 

The joining of Inconel 625 and GRCop42 using additive manufacturing is required for thermal management of high operating temperature components. Though prior efforts have been made to use laser directed energy deposition to join these materials, the impact of laser power and deposition sequence on microstructure of these joints is not well understood. In this study, Inconel 625 onto GRCop42 and GRCop42 onto Inconel 625 joints are fabricated by wire- powder laser directed energy deposition (WPLDED) at various laser powers and subsequently subjected to characterization in terms of present defects, grain morphology, and phases. WP-DED provides the unique capability of producing tailored multi-material components that have the high deposition rates of wire-based LDED combined with the high resolution and complexity found in powder-based LDED.  Results show lack-of-fusion free Inconel 625 onto GRCop42 joints can be fabricated by increasing the laser power in the first layer. Substrate remelting in GRCop42 onto Inconel 625 joints is found to result in a melt pool composition which induces liquid-state immiscibility, resulting in a Cu-deprived liquid solidifying to form crack prone islands. Increasing laser power decreases the embrittlement of these islands due to the precipitation of a lower volume fraction of intermetallic phases. As a powerful but complex process, understanding the thermal profile of the WPLDED process along with solidification morphology such as dimensional accuracy and weight percentages of each material are important to study.  Thus, a coaxial wire-fed powder-fed system is simulated through the development of a computational fluid dynamics (CFD) numerical model.  This model can capture in-situ thermal profiling and heat transfer interactions within the process, while simultaneously capable of providing bead dimensions and weight percentages of the individual materials for wire and powder.  Simulation results were validated against experimental data, providing a prediction method for the CWP-DED process.

Presenting Author: Somayeh Pasebani Oregon State University

Presenting Author Biography: Somayeh Pasebani is an associate professor in advanced manufacturing within the School of Mechanical Engineering at Oregon State University. She has co-authored over 50 peer-reviewed publications and secured numerous grants from prestigious organizations such as NSF, DOE, ONR, AFRL, and industrial partners. She has been honored with the NSF CAREER award for understanding the joining mechanisms in dissimilar metal additive manufacturing. Her research primarily focuses on metal additive manufacturing, particularly in high-temperature alloys, ODS alloys, multi-material AM (graded alloys), and tailored alloys. Prior to joining OSU, Pasebani worked at Hoganas, contributing to their research and development endeavors. Holding a PhD in Materials Science, her expertise lies in powder metallurgy and metal additive manufacturing.

Authors:

Somayeh Pasebani Oregon State University
Stephanie Lawson Oregon State University
Jakub Preis Oregon State University