Abstract
Processing, microstructure, and mechanical properties of the hybrid electron beam powder bed fusion (E-PBF) additive manufacturing of Ti–6Al–4V have been investigated. We explore the possibility of integrating the substrate as a part of the final component as a repair, integrated, or consolidated part. Various starting plate surface conditions are used to understand the joining behavior and their microstructural properties in the bonding region between the plate and initial deposited layers. It is found that mechanical failures mainly occur within the substrate region due to the dominant plastic strains localized in the weaker Ti–6Al–4V substrate. The hybrid concept is successfully proven with satisfactory bonding performance between the E-PBF build and substrate. This investigation improves the practice of using the hybrid E-PBF additive manufacturing technique and provides basic understanding to this approach.
Highlights
CURRENTLY, the increase in productivity is one of the main pursuing areas of investigation in additive manufacturing (AM)
An imbedded sensor was VOLUME 53A, MARCH 2022—927 manufactured through six steps and two builds to enclose an alumina sensor inside a Ti–6Al–4V part manufactured by electron beam powder bed fusion (E-powder bed fusion (PBF))
They managed to build on the top side of a previously manufactured AMed part in E-PBF, leveling it with the starting plate and building up the final sealing part which sealed the part to a monoblock component
Summary
CURRENTLY, the increase in productivity is one of the main pursuing areas of investigation in additive manufacturing (AM). A microstructural investigation showed strong bonding in the transition zone This technique demonstrated the flexibility of building on top of existing parts using a conventional machine adapted to the final goal of the experiment, which opens several possibilities such as adding material to existing or worn parts or manufacturing multi-material components. A ‘‘stop and go process’’ was performed by Hossain et al.[10] Using several manufacturing steps, an imbedded sensor was VOLUME 53A, MARCH 2022—927 manufactured through six steps and two builds to enclose an alumina sensor inside a Ti–6Al–4V part manufactured by E-PBF They managed to build on the top side of a previously manufactured AMed part in E-PBF, leveling it with the starting plate and building up the final sealing part which sealed the part to a monoblock component. This study investigates a hybrid AM method using the starting plate as an integrated part of the substrate, and aims to exploring an effective way of significantly improving productivity of E-PBFed Ti–6Al–4V
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