| 1. |
- Mahade, Satyapal, 1987-, et al.
(author)
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Incorporation of graphene nano platelets in suspension plasma sprayed alumina coatings for improved tribological properties
- 2021
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In: Applied Surface Science. - : Elsevier BV. - 0169-4332 .- 1873-5584. ; 570
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Journal article (peer-reviewed)abstract
- Graphene possesses high fracture toughness and excellent lubrication properties, which can be exploited to enhance tribological performance of coating systems utilized to combat wear. In this work, suspension plasma spray (SPS) process was employed to deposit a composite, graphene nano-platelets (GNP) incorporated alumina coating. For comparison, monolithic alumina was also deposited utilizing identical spray conditions. The as-deposited coatings were characterized in detail for their microstructure, porosity content, hardness, fracture toughness and phase composition. Raman analysis of the as-deposited composite coating confirmed retention of GNP. The composite coating also showed good microstructural integrity, comparable porosity, higher fracture toughness and similar alumina phase composition as the monolithic alumina coating. The as-deposited coatings were subjected to dry sliding wear tests. The GNP incorporated composite coating showed lower CoF and lower specific wear rate than the pure alumina coating. Additionally, the counter surface also showed a lower wear rate in case of the composite coating. Post-wear analysis performed by SEM/EDS showed differences in the coating wear track and in the ball wear track of monolithic and composite coatings. Furthermore, Raman analysis in the wear track of composite coating confirmed the presence of GNP. The micro-indentation and wear test results indicate that the presence of GNP in the composite coating aided in improving fracture toughness, lowering CoF and specific wear rate compared to the monolithic coating. Results from this work demonstrated retention of GNP in an SPS processed coating, which can be further exploited to design superior wear-resistant coatings.
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| 2. |
- Goel, Sneha, 1993-, et al.
(author)
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Effect of post-treatments under hot isostatic pressure on microstructural characteristics of EBM-built Alloy 718
- 2019
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In: Additive Manufacturing. - : Elsevier BV. - 2214-8604 .- 2214-7810. ; 28, s. 727-737
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Journal article (peer-reviewed)abstract
- Electron beam melting (EBM) has emerged as an important additive manufacturing technique. In this study, Alloy 718 produced by EBM was investigated in as-built and post-treated conditions for microstructural characteristics and hardness. The post-treatments investigated were hot isostatic pressing (HIP) and combined HIP + heat treatment (HIP + HT) carried out as a single cycle inside the HIP vessel. Both the post-treatments resulted in significant decrease in defects inevitably present in the as-built material. The columnar grain structure of the as-built material was found to be maintained after post-treatment, with some sporadic localized grain coarsening noted. Although HIP led to complete dissolution of δ and γ′′ phase, stable NbC and TiN (occasionally present) particles were observed in the post-treated specimens. Significant precipitation of γ′′ phase was observed after HIP + HT, which was attributed to the two-step aging heat treatment carried out during HIP + HT. The presence of γ′′ phase or otherwise was correlated to the hardness of the material. While the HIP treatment resulted in drop in hardness, HIP + HT led to ‘recovery’ of the hardness to values exceeding those exhibited by the as-built material.
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| 3. |
- Goel, Sneha, 1993-, et al.
(author)
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The Effect of Location and Post-treatment on the Microstructure of EBM-Built Alloy 718
- 2018
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In: Proceedings of the 9th International Symposium on Superalloy 718 & Derivatives. - Cham : Springer. - 2367-1696 .- 2367-1181. - 9783319894799 - 9783319894805 ; , s. 115-129
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Conference paper (peer-reviewed)abstract
- Additive manufacturing (AM) of Ni-based superalloys such as Alloy 718 may obviate the need for difficult machining and welding operations associated with geometrically intricate parts, thus potentially expanding design possibilities and facilitating cost-effective manufacture of complex components. However, processing AM builds completely free from defects, which may impair mechanical properties such as fatigue and ductility, is challenging. Anisotropic properties, microstructural heterogeneities and local formation of undesired phases are additional concerns that have motivated post-treatment of AM builds. This work investigates the microstructural changes associated with post-treatment of Alloy 718 specimens produced by Electron Beam Melting (EBM) for as-built microstructures at 3 build heights: near base plate, in the middle of build and near the top of the build. Two different post-treatment conditions, hot isostatic pressing (HIP) alone and a combined HIP with solutionising and two-step aging were examined and compared to the results for the as-built condition. The influence of various post-treatments on minor phase distributions (δ, γ″, carbides), overall porosity, longitudinal grain widths and Vickers microhardness was considered. The HIP treatment led to significant reduction in overall porosity and dissolution of δ phase, which led to appreciable grain growth for both post-treatment conditions. The variation in hardness noted as a function of build height for the as-built specimens was eliminated after post-treatment. Overall, the hardness was found to decrease after HIP and increase after the full HIP, solutionising and aging treatment, which was attributed to dissolution of γ″ during HIP and its re-precipitation in subsequent heat treatment steps.
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| 4. |
- Ganvir, Ashish, 1991-, et al.
(author)
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Novel utilization of liquid feedstock in high velocity air fuel (HVAF) spraying to deposit solid lubricant reinforced wear resistant coatings
- 2021
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In: Journal of Materials Processing Technology. - : Elsevier BV. - 0924-0136 .- 1873-4774. ; 295
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Journal article (peer-reviewed)abstract
- The ability to axially inject liquid feedstock has encouraged the thermal spray research community to explore this concept to deposit coatings for various next generation functional applications. The current study explores the utilization of liquid feedstock in high velocity air fuel (HVAF) spraying to deposit solid lubricant reinforced wear resistant coatings for the first time. The study successfully demonstrates the use of a powder-suspension hybrid processing approach to incorporate a solid lubricant Boron Nitride (as suspension) in a wear resistant Cr3C2–NiCr (as powder) cermet matrix. Coatings were characterized using Scanning Electron Microscopy and Raman Spectroscopy to analyze their microstructure and phase constitution. The results show that the tribological performance of the hexagonal boron nitride (hBN)-incorporated composite coating was significantly better than the traditional powder-derived Cr3C2–NiCr coating. Such hBN-incorporated composite coatings are needed to improve the mechanical properties and enhance the overall tribological performance of metallic components used in various applications, especially at high temperature such as cylinder bore, pistons, deformation tools, etc. The limitations of liquid based lubricants at high temperature motivates the use of hBN reinforced composite coatings as it can form a protective solid lubrication tribo-film. The study concludes that the emerging HVAF technology can accommodate liquid feedstock and be successfully utilized to deposit hybrid powder-suspension composite coatings to create multi length scale microstructures which can be attractive for combining different tribological attributes in the same coatings system.
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| 5. |
- Goel, Sneha, 1993-, et al.
(author)
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Residual stress determination by neutron diffraction in powder bed fusion-built Alloy 718: Influence of process parameters and post-treatment
- 2020
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In: Materials and Design. - : Elsevier BV. - 1873-4197 .- 0264-1275. ; 195
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Journal article (peer-reviewed)abstract
- Alloy 718 is a nickel-based superalloy that is widely used as a structural material for high-temperature applications. One concern that arises when Alloy 718 is manufactured using powder bed fusion (PBF) is that residual stresses appear due to the high thermal gradients. These residual stresses can be detrimental as they can degrade mechanical properties and distort components. In this work, residual stresses in PBF built Alloy 718, using both electron and laser energy sources, were measured by neutron diffraction. The effects of process parameters and thermal post-treatments were studied. The results show that thermal post-treatments effectively reduce the residual stresses present in the material. Moreover, the material built with laser based PBF showed a higher residual stress compared to the material built with electron-beam based PBF. The scanning strategy with the lower amount of residual stresses in case of laser based PBF was the chessboard strategy compared to the bi-directional raster strategy. In addition, the influence of measured and calculated lattice spacing (d0) on the evaluated residual stresses was investigated.
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| 6. |
- Goel, Sneha, 1993-, et al.
(author)
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Can Appropriate Thermal Post-Treatment Make Defect Content in as-Built Electron Beam Additively Manufactured Alloy 718 Irrelevant?
- 2020
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In: Materials. - : MDPI AG. - 1996-1944. ; 13:3
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Journal article (peer-reviewed)abstract
- Electron beam melting (EBM) is gaining rapid popularity for production of complex customized parts. For strategic applications involving materials like superalloys (e.g., Alloy 718), post-treatments including hot isostatic pressing (HIPing) to eliminate defects, and solutionizing and aging to achieve the desired phase constitution are often practiced. The present study specifically explores the ability of the combination of the above post-treatments to render the as-built defect content in EBM Alloy 718 irrelevant. Results show that HIPing can reduce defect content from as high as 17% in as-built samples (intentionally generated employing increased processing speeds in this illustrative proof-of-concept study) to <0.3%, with the small amount of remnant defects being mainly associated with oxide inclusions. The subsequent solution and aging treatments are also found to yield virtually identical phase distribution and hardness values in samples with vastly varying as-built defect contents. This can have considerable implications in contributing to minimizing elaborate process optimization efforts as well as slightly enhancing production speeds to promote industrialization of EBM for applications that demand the above post-treatments.
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| 7. |
- Kumara, Chamara, et al.
(author)
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Microstructure modelling of laser metal powder directed energy deposition of alloy 718
- 2019
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In: Additive Manufacturing. - : Elsevier. - 2214-8604 .- 2214-7810. ; 25, s. 357-364
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Journal article (peer-reviewed)abstract
- A multi-component and multi-phase-field modelling approach, combined with transformation kinetics modelling, was used to model microstructure evolution during laser metal powder directed energy deposition of Alloy 718 and subsequent heat treatments. Experimental temperature measurements were utilised to predict microstructural evolution during successive addition of layers. Segregation of alloying elements as well as formation of Laves and δ phase was specifically modelled. The predicted elemental concentrations were then used in transformation kinetics to estimate changes in Continuous Cooling Transformation (CCT) and Time Temperature Transformation (TTT) diagrams for Alloy 718. Modelling results showed good agreement with experimentally observed phase evolution within the microstructure. The results indicate that the approach can be a valuable tool, both for improving process understanding and for process development including subsequent heat treatment.
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| 8. |
- Goel, Sneha, 1993-, et al.
(author)
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Microstructure evolution and mechanical response-based shortening of thermal post-treatment for electron beam melting (EBM) produced Alloy 718
- 2021
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In: Materials Science and Engineering. - : Elsevier BV. - 0921-5093 .- 1873-4936. ; 820
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Journal article (peer-reviewed)abstract
- Electron beam melting (EBM) produced Alloy 718 was subjected to thermal post-treatment involving hot isostatic pressing (HIPing) and heat treatment (HT). Subjecting the material to HIPing at 1120 °C led to significant densification. Study of microstructure evolution during HT (comprising of solution treatment and aging) showed possibility of significantly shortening the HT duration, particularly the time for two-step aging from the standard (8 h + 8 h) long cycle to possibly a shortened (4 h + 1 h) cycle. Another approach for shortening the post-treatment cycle by integrating the HIPing with HT inside the HIP vessel was also successfully implemented. The above observations were further substantiated by tensile response of the material subjected to the varied post-treatment cycles; out of all the post-treatments steps, tensile behaviour was observed to be mainly affected by the aging treatment. Further prospects for shortening the post-treatment protocol are also described, such as shortening of HIPing duration for the typical 4 h to 1 h cycle as well as possible elimination of solution treatment step from the entire post-treatment protocol specifically when prior HIPing is performed. Heat treatment with prior HIPing was found to be crucial for improving fatigue life, because subjecting EBM Alloy 718 to only HT, irrespective of the short or standard long protocol, rendered inferior fatigue response.
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| 9. |
- Goel, Sneha, 1993-, et al.
(author)
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Microstructure evolution-based design of thermal post-treatments for EBM-built Alloy 718
- 2020
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In: Journal of Materials Science. - : Springer Science and Business Media LLC. - 0022-2461 .- 1573-4803. ; 56:2, s. 5250-5268
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Journal article (peer-reviewed)abstract
- Alloy 718 samples were fabricated by electron beam melting (EBM) additive manufacturing process. The work focused on systematic investigation of response of the material to various thermal post-treatments, involving hot isostatic pressing (HIPing), solution treatment (ST) and two-step aging, to tailor post-treatment procedure for EBM-built Alloy 718. Results showed that HIPing at lowered temperature can be used for attaining desired defect closure while preserving grain size. Subjecting the material to ST, with or without prior HIPing, mainly caused precipitation of δ phase at the grain boundaries with prior HIPing decreasing the extent of δ phase precipitation. Moreover, results suggest that the utility of ST, with prior HIPing, could be dictated by the need to achieve a certain δ phase content, as the typically targeted homogenization after ST had already been achieved through HIPing. Detailed investigation of microstructural evolution during subsequent aging with and without prior HIPing showed that a significantly shortened aging treatment (‘4 + 1’ h), compared to the ‘standard’ long treatment (‘8 + 8’ h) traditionally developed for conventionally produced Alloy 718, might be realizable. These results can have significant techno-economic implications in designing tailored post-treatments for EBM-built Alloy 718.
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| 10. |
- Gundgire, Tejas, 1994-, et al.
(author)
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Response of different electron beam melting produced Alloy 718 microstructures to thermal post-treatments
- 2020
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In: Materials Characterization. - : Elsevier BV. - 1044-5803 .- 1873-4189. ; 167
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Journal article (peer-reviewed)abstract
- Electron beam melting (EBM) was used to produce Alloy 718 specimens with different microstructures (columnar, equiaxed and a combination thereof) by varying the process parameters. The present study aimed at assessing the response of such varying as-built microstructures to identical thermal post-treatments, which included hot isostatic pressing (HIPing) followed by heat treatment involving solution treatment and aging. The effect of these treatments on defect content, grain structure, hardness and phase constitution in the specimens was specifically analysed. Despite differences in defect content of as-built specimens with distinct microstructures, HIPing was effective in closing defects leading to samples exhibiting similar density. After HIPing, grains with equiaxed morphology or columnar grains with lower aspect ratio showed higher tendency for grain growth in comparison to the columnar grains with higher aspect ratio. The various factors affecting the stability of grains during HIPing of builds with distinct microstructures were investigated. These factors include texture, grain size, and secondary phase particles. The carbide sizes in the different as-built samples varied but were found to be largely unaffected by the post-treatments. Solution treatment following HIPing led to greater precipitation of grain boundary ÎŽ phase in regions with coarser grains than the smaller ones. After HIPing and heat treatment, all specimens exhibited similar precipitation of γ″ phase regardless of their grain morphology in the as-built condition. © 2020 The Author(s)
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