Session: 16-01-01: Government Agency Student Poster Competition

Paper Number: 150791

150791 - Mechanical Behavior of Fe-Mn-Al-Ni Shape Memory Alloy Processed by Additive Manufacturing 

The demand for cost-effective shape memory alloys (SMAs) to enhance the performance of large-scale applications, such as civil structures, has contributed to the increased interest in the investigation of Fe-based SMAs since these alloys are substantially less expensive than the available SMAs, have good workability and weldability, as well as exhibit stable superelasticity over a wide temperature range. Laser powder bed fusion (LPBF) has contributed to significant strides in additive manufacturing, resulting in reduced lead times and costs, new materials and creative design solutions, mass decrease in components through lightweight and extremely effective designs, and multi-material fabrication for risk mitigation or performance improvement, which allows for the design and modification of SMAs with improved properties. LPBF provides an intriguing technique for manufacturing customized Fe-Mn-Al-based shape memory alloys with tailored microstructures and mechanical properties. Optimization of LPBF process parameters is imperative for fully leveraging the potential of these smart materials in numerous applications including damping civil structures, adaptive structures, actuators, crane rail, and pipe industries, among others.

In the present work, the Fe-Mn-Al-Ni shape memory alloy, an advanced SMA with great processability, high functional stability, and good superelastic behavior, was successfully fabricated via LPBF using a laser power (LP) range of 150 W to 200 W and laser scanning speed (LSS) of 600 mm/s to 800 mm/s. This yielded in the manufacturing of 18 Fe-Mn-Al-Ni specimens with varying energy inputs (VED) ranging from 50 J.mm³-133 J.mm³. In order to investigate the effect of the processing window on the mechanical behavior of the LPBF-manufactured Fe-Mn-Al-Ni SMA, the fabricated specimens were evaluated for their mechanical characteristics, including nano-hardness (h_n), micro-hardness(h_µ), modulus of elasticity (E), strength (UTS), and ductility (EL), using profilometry-based indentation plastometry, microindentation, and nanoindentation techniques.  The observed variations in VED, derived from various combinations of process parameters, have been attributed to a variable mechanical performance in the LPBF-manufactured Fe-based SMA, which validates the impact of VED variations on the microstructure and material development. The findings demonstrate that Fe-Mn-Al-Ni SMA produced using an LP of 175 W combined with an LSS 800 mm/s (73 J.mm³) achieved the optimal mechanical properties indulging h_n, h_µ, E, UTS, and EL of approximately  5 GPa, 448 HV, 158 GPa, 17 % and 1466 MPa, respectively. The observed characteristics of LPBF-produced Fe-Mn-Al-Ni SMA align well with previous investigations that utilized conventional manufacturing techniques. This study indicates that the LPBF technique can be a feasible route for the fabrication and development of Fe-Mn-Al-Ni SMA with properties comparable to the conventional alloy.

Presenting Author: Anwar Algamal University of Toledo

Presenting Author Biography: Anwar is a PhD candidate in the Mechanical, Industrial & Manufacturing Engineering Department at The University of Toledo. His research focuses on the development and manufacturing of smart metallic materials, with a particular focus on Fe-based shape memory alloys. He is leveraging the potential of laser powder bed fusion technology to manufacture intricate geometries and precise microstructures in SMAs, such as Fe-Mn-Al-Ni alloys, enabling their application in aerospace, structural components, and automotive industries. Throughout his research, Answer has published impactful journal articles and conference proceedings presenting his findings and advances in metal additive manufacturing, SMAs, and sustainable materials.

Authors:

Anwar Algamal University of Toledo
Gabriel Dzukey University of Toledo
Sara Ranjbareslamloo University of Toledo
Ala Qattawi University of Toledo