Aluminum alloys – strong, tough, and lightweight – are desirable materials for aerospace, marine, and defense applications. When processed using laser powder bed fusion, however, these alloys have a tendency to crack and distort.
To mitigate this problem, EWI recently tested blending AA7075 with AlSi10Mg powder. The results show great promise for successful laser additive manufacturing processing.
You are invited to read about this work in a paper by EWI Senior Technology Leader Alber Sadek, , Laser Powder Bed Fusion of AA7075 Alloy with Additional Si+Mg Content. To download the paper at no charge, simply complete the form on this page.
To speak to the author about this research or to learn more about materials development at EWI, contact [email protected].
Complete the form to download the paper:
To view the paper, please submit the form above.
Want to contact an EWI expert about a project? Call 614.688.5152 or click here.
EWI, GE Research (GER), and the University of South Carolina (U of SC) have just begun a $5 million program funded by the Department of Energy in which machine learning is used to develop the process for building a functionally graded material for energy applications.
The specific goal is to develop net-shape manufacturing technologies for high γ’ to low γ’ nickel superalloy functionally graded materials (FGM) using laser-blown powder directed energy deposition (L-DED) for manufacturing hot-and-harsh gas path (HGP) parts in gas turbines or jet engines. The objective is to reduce material and manufacturing costs by 10-20% and improve durability by 20-30%. The program is summarized in Figure 1.
To successfully build this challenging FGM, the team is developing a systematic process which can be extended to other material combinations. Several of the planned developments are highlighted below.
Faster Development
The parameter space for DED FGMs is extensive. It includes the parameters to build each terminal alloy as well as the strategy and associated parameters for the transition region. Further, for precipitation hardened materials, thermal post-processing must be considered from the outset. Finally, the interaction terms between process parameters are known to be strong.
To efficiently work in this complex space, GER’s Bayesian Hybrid Model (BHM) and Intelligent Design and Analysis of Computer Experiments will be applied. These methods are a probabilistic approach which allow the inclusion of modeling results.
Process-Monitoring for Model Validation
As inputs into the BHM, U of SC is developing microstructural and defect models and GER is developing stress and distortion models. These models are being validated against process monitoring at EWI and beam-line characterization at Oak Ridge National Lab and Argonne National Lab. EWI is advancing its L-DED process monitoring to facilitate better data registration between sensor measurements, modeling results, and characterization results.
Process Modifications:
EWI process experts have identified process improvements for FGM buildability. Concepts include a heated build plate, modified powder mixing, and laser stirring. These modifications should mitigate crack formation causes such as residual stress, but they further complicate the parameter space. Modeling and machine learning will be used to guide their use.
Summary of initiated work
If you are interested in learning more about this program as it progresses, please contact Alex Kitt, EWI Director of Data Science, at [email protected].
How can you harness the power of high-power ultrasonic technology to optimize your manufacturing processes?
EWI Project Engineer Amin Moghaddas recently developed a technique using special resolution V design and RSM to characterize and optimize ultrasonic-assisted drilling for aluminum 6061. This work is discussed in his paper, Modeling and Optimization of Ultrasonic-Assisted Manufacturing Process.
You may download this paper at no charge by completing the form on this page.
If you would like to learn more about this research or have questionsabout EWI’s work in high-power ultrasonics, contact [email protected].
Complete the form to download the paper:
To view the paper, please submit the form above.
To speak to an EWI expert about a project, call 614.688.5152 or click here.
EWI is pleased to welcome Crenlo to membership. Crenlo is a leading manufacturer of engineered steel frame cab enclosures and rollover structures serving major OEM’s in the construction, agriculture, and commercial equipment markets. Crenlo also produces a proprietary line of electronic enclosures under its EMCOR trademark, which serves the commercial, telecom, datacom, test & measurement, broadcast, and security markets.
When designing a new medical product, manufacturers need to qualify their materials and processes early in development to ensure a successful launch. This is especially true with when using polymers in a device that must be biocompatible, resistant to chemicals and liquids, and strong enough to withstand constant use.
A new guide by EWI polymer engineers Jeff Ellis and Miranda Marcus, Designing Plastic Medical Devices: Materials and Process Considerations, helps product developers evaluate their designs early in the development stage to avoid process pitfalls and costly mistakes long before a new concept gets to production.
You are invited to download this guide — at no charge — by completing this form:
Are you looking for ways to enhance the manufacturability of your medical device right now? Contact Jeff Ellis at [email protected] for assistance today.
To view the paper, please submit the form above.
To speak to an EWI expert about a project, call 614.688.5152 or click here.
The EWI Skillform Center is pleased to announce the opening of its new Robotics Training Lab, designed specifically for teaching. This new lab gives EWI the ability to teach professionals about applied automation in a hands-on environment.
The Robotics Training Lab, based at EWI’s Buffalo, NY, facility, features ten brand new state-of-the-art automation cells which can accommodate robotic training on both industrial and collaborative platforms. EWI will be offering several robotic training classes in the coming months that will help familiarize participants with an array of industrial robots and help them understand options for automation in both small and large production settings.
The first class, Introduction to Robotics, will be held on March 10th. This one-day course will give participants experience in basic robot motion on both industrial and collaborative robots as well as review basic safety considerations for implementing robots. Attendees can earn 6 PDH for the course. Class size will be kept small to ensure a safe learning environment adherent to CDC COVID guidelines, so spaces are limited.
To sign up for the Introduction to Robotics class in March, click here.
Springback is a critical challenge of forming and welding sheet metal parts for manufacturing applications in the aerospace, automotive, energy, electronics, and heavy manufacturing industries. Springback measurements can vary with material properties, stress-strain variables, part geometry, friction between forming tools, etc. It is difficult to eliminate springback during cold forming processes, but it can be controlled by compensating for the resulting dimensional change.
There are numerous considerations for welding formed parts where springback is present. For example, the clamping forces in tooling must be adequately addressed to ensure optimum joint fit-up for welding. Reliable prediction and practical compensation of springback forces are imperative to maximized weld quality and stabilize fabrication processes.
The automotive industry is increasingly adopting advanced high-strength steel (AHSS) and high-strength aluminum alloys for the automotive body structure. Newly emerging generation-3 AHSS and high-strength aluminum alloys are starting to be used in production and stampers addressed increased challenges with the increased springback of these emerging materials.
Comparison of springback of three selected materials in a S-rail part
EWI forming team recently developed a new springback test tooling to evaluate and control the springback of selected aluminum 6xxx alloys and GEN3 steel using an S-rail part and a 300-ton servo press. Preliminary simulation results showed springback of GEN980 steel and AA6016 to be 5x and 4x larger, respectively, than a conventional AHSS, dual-phase 780 material (see figures above). When the tooling is completely fabricated in early spring, EWI will investigate the effects of the following key variables on springback for selected GEN3 and aluminum alloys.
Material flow curves, kinematic hardening, and yield function models
Variation of the incoming material properties from multiple batch materials
Stake-beads on the tool
Servo press slide and binder force profiles
EWI also plans to use a real-time visual monitoring system to monitor the part springback. The monitoring system is very practical and useful to measure springback in a production environment.
For more information, please contact Hyunok Kim, Forming Center Director, at [email protected] or 614.688.5239.
With the rapid acceleration of additive manufacturing (AM) throughout industry, there is a need for high-quality, affordable metal powders. Material requirements can vary depending on the process and system used, and frequently custom process parameters for new powder must be developed.
Whether you are a powder developer looking to certify your
product or a manufacturer seeking tested, reliable feedstock for your AM
operation, it is essential to have an unbiased evaluation to confirm the
quality of your powder.
EWI
offers a complete suite of validation services for powder suppliers and their
clients who use powders in any application. With a full range of testing and
measurement resources available in our labs, EWI has the resources and
expertise to provide confidence in powder consistency, quantify variability
within a supplier’s batches, define the impact of recycling on powder
properties, and create a starting point for future powder development.
To learn more about EWI’s metal powder evaluation services, click here.
To
contact EWI for immediate help with developing, qualifying, or enhancing the
quality of metal powders, contact [email protected] or 614.688.5152.
