MICROSTRUCTURE ARCHITECTURE DEVELOPMENT IN METALS AND ALLOYS BY ADDITIVE MANUFACTURING USING ELECTRON BEAM MELTING

摘要

The concept of materials with controlled microstructural architecture (MCMA) to develop and fabricate structural materials with novel and possibly superior properties and performance characteristics is a new paradigm or paradigm extension for materials science and engineering. In the conventional materials science and engineering paradigm, structure (microstructure), properties, processing, and performance features are linked in the development of desirable materials properties and performance through processing methodologies which manipulate microstructures. For many metal or alloy systems, thermomechanical treatment combining controlled amounts of plastic deformation with heat treatment or aging cycles can achieve improved mechanical properties beyond those attainable by conventional processing alone (such as rolling or forging for example) through controlled microstructure development. In this paper we illustrate a new concept involving the fabrication of microstructural architectures by the process development and selective manipulation of these microstructures ideally defining material design space. This allows for the additional or independent manipulation of material properties by additive manufacturing (AM) using electron beam melting (EBM). Specifically we demonstrate the novel development of a carbide (M23C6) architecture in the AM of a Co-base alloy and an oxide (CU2O) precipitate-dislocation architecture in the AM of an oxygen-containing Cu. While more conventional processing can produce various precipitate microstructures in these materials, EBM produces spatial arrays of precipitate columns or columnar-like features often oriented in the build direction. These microstructural architectures are observed by optical microscopy and scanning and transmission electron microscopy. Prospects for EBM architecture development in precipitation-hardenable Al alloys is also discussed. In the EBM build process using precursor powders, the electron beam parameters (including beam focus, scan speed and sequencing) produce localized, requisite thermodynamic regimes which create or organize the precipitate-related spatial arrays. This feature demonstrates the utility of AM not only in the fabrication of complex components, but also prospects for selective property design using CAD for MCMA development: a new or extended processing-microstructure-property-performance paradigm for materials science and engineering in advanced manufacturing involving solid free-form fabrication (SFF).