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Additive Manufacturing Technique

This document discusses additive manufacturing of gamma titanium aluminide parts using electron beam melting. It provides an introduction to EBM and Arcam AB, describes developing an EBM process for gamma TiAl including powder properties and microstructure, and reports on mechanical properties including tensile, fatigue and creep. Key findings are that EBM gamma TiAl meets or exceeds reference material properties and serial production is being launched.

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100 views29 pages

Additive Manufacturing Technique

This document discusses additive manufacturing of gamma titanium aluminide parts using electron beam melting. It provides an introduction to EBM and Arcam AB, describes developing an EBM process for gamma TiAl including powder properties and microstructure, and reports on mechanical properties including tensile, fatigue and creep. Key findings are that EBM gamma TiAl meets or exceeds reference material properties and serial production is being launched.

Uploaded by

john kasich
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Additive Manufacturing of Gamma Titanium Aluminide

Parts by Electron Beam Melting (EBM®)


Ulf Ackelid, M. Svensson, Arcam AB, Sweden
S. Sabbadini, F. Pelissero, Avio SpA, Italy
P. Gennaro, AvioProp SrL, Italy
M. Filippini, S. Beretta, Politecnico di Milano, Italy
S. Biamino, A. Penna, M. Pavese, S. Marchisio, P. Fino, C. Badini, Politecnico di Torino, Italy
Outline

• Introduction to Electron Beam Melting


• Arcam AB
• EBM process
• EBM materials
• EBM applications
• New EBM process for -TiAl
• Powder properties
• Heat treatment and microstructure
• Chemical composition
• Tensile properties
• Fatigue properties
• Summary and conclusion
What is Arcam?

• Develops technology for additive


manufacturing with EBM
• Swedish innovation, early 1990’s
• Arcam AB founded 1997
• Located in Gothenburg, Sweden
• First EBM machine delivered in 2003
• More than 60 systems installed worldwide
• Main focus (so far): Medical implants and
aerospace parts made from titanium alloys
• Some well-known EBM users:
Boeing, NASA, Airbus
The EBM process
• Typical powder size:
45-105 μm (-140/+325 mesh)

• Layer thickness:
0.05-0.2 mm

• 3kW electron beam

• Elevated build temperature,


e.g. Ti-6Al-4V, ~700C
-TiAl, >1000C

• High vacuum:
10-5 mbar

• Build rate:
3-20 mm height/hour

• Build envelope:
up to 350200200 mm (1488 in.)
EBM metal powders

• Pre-alloyed
• Supplied by selected powder manufacturers
• No binders or additives
• Size fraction selected for safety and production economy
• Provided with optimized EBM machine parameters
EBM materials

• ”Commercial” processes developed for:


• Ti-6Al-4V (Grade 5)
• Ti-6Al-4V-ELI (Grade 23)
• Titanium CP (Grade 2)
• CoCr alloy F75
• Gamma-TiAl, Ti-48Al-2Cr-2Nb

• Full compliance with ISO and ASTM


standards

• Any metal with a melting point up to


tungsten (3400C) can be melted with a
3kW e-beam.
Other materials with proven EBM potential

• Ni-based superalloys (e.g. Alloy 625 & 718)


• Stainless steel (e.g. 17-4)
• Tool steel (e.g. H13)
• Aluminium (e.g. 6061)
• Hard metals (e.g. Ni-WC)
• Copper
• Beryllium
• Amorphous metals
• Niobium
• Invar
EBM applications

• Medical Implants

• Aerospace

• Automotive

• Other
CE-certified implant production since 2007

• Acetabular cups with engineered trabecular structures


• Ti-6Al-4V ELI, 12 cups in 13 hours, stackable 82 cups in
80 h
• > 35000 cups manufactured
• Approx. 7000 cups implanted
Turbine blades in -TiAl
• TiAl collaboration project with Avio SpA in Italy
• Demo turbine blades for the LP stage in GEnx engine
• 325 mm build height
• Dimensional tolerance 0.1 mm
• Net build time 7 h / blade
• Turnaround time 10 h / blade
Development of an EBM process for -TiAl (Ti-48Al-2Cr-2Nb)
Incentive

• -TiAl is an attractive material for structural aerospace applications at high T:


• Good oxidation and corrosion resistance
• Specific strength comparable to Ni-base superalloys
• Density about 50% of Ni-base superalloys
• Ti-48Al-2Cr-2Nb is the most well-characterized -TiAl alloy

• Advantages of the EBM process:


• low level of internal defects, therefore low scatter in material properties
• homogeneous microstructure
• very fine grain size, leading to good fatigue properties, and no need for
grain refinement
• no residual stresses due to high process temperature
• little waste material thanks to vacuum environment: powder can be
recycled
Reference data for Ti-48Al-2Cr-2Nb

M.J. Weimer, T.J. Kelly, GE Aviation:


TiAl Alloy 48Al-2Nb-2Cr: Material Database and Application Status

Cast Ti-48Al-2Cr-2Nb, HIP + HT, duplex microstructure

Presented at the 3rd International Workshop on -TiAl Technologies,


Bamberg, Germany, May 29-31, 2006
EBM -TiAl Powder Properties

• Vacuum induction melted, Ar gas atomized


• Size 45-150 µm (-100/+325 mesh)

• Spherical pores < 150 μm


• Originate from Ar bubbles
entrapped in the powder
• Closed by HIP
EBM -TiAl Chemical Composition

Chemical composition in wt%

Al Cr Nb Fe C O N H Ti

Ti-48Al-2Cr-2Nb Max. Max. Max. Max. Max.


32.0 - 33.5 2.2 - 2.6 4.5 - 5.1 Bal.
Alloy specification 0.05 0.025 0.12 0.02 0.003

Powder X 34.1 2.4 4.8 0.03 0.005 0.06 0.004 0.001 Bal.
Material built with
33.4 2.2 5.1 0.03 0.008 0.06 0.01 0.0001 Bal.
Powder X

• Approx. 1 wt% Al loss due to evaporation

• Modified powder chemistry, +1 wt% Al

• Very low pickup of O and N thanks to vacuum environment


EBM -TiAl Microstructures

As-built by EBM

HIP 1260C, 1700 bar, 4h


Equiaxed 
Grain size <20m Heat Treatment
Duplex
Lamellar colonies ~100 m
Equiaxed grains ~15 m
Lamellar fraction ~ 40%
EBM -TiAl Tensile Properties

• UTS/YTS virtually independent of temperature up to ~815C


• Brittle-Ductile Transition Temperature (BDTT) between 700 - 800°C
• Similar behavior as cast material
• Ref. UTS=450 MPa (65 ksi) in GE database
EBM -TiAl Tensile Properties, scattering

• 10% scattering of UTS and 6% of YTS at room temperature, based on >10


tensile specimens per data point
• Low scattering compared to cast γ-TiAl and also compared to cast Ni-superalloys

19
EBM -TiAl Tensile Properties, after ageing

• Aged in air at 650 °C for 10 h


• Loss of ductility at lower temperatures compared to non-oxidized
• Machining of the surface restores ductility → surface effect !
• Similar loss of ductility has been reported for oxidized cast TiAl
EBM -TiAl Fatigue Crack Growth Threshold

Constant amplitude crack growth


with load increase

RT, 40 Hz, R=0.05

6.13 < Kth < 6.70 MPa·m½

GE reference: Kth = 4.7 MPa·m½


EBM -TiAl HCF Properties, RT
EBM -TiAl Fatigue Properties, 704C (1300 F)

• Ref. fatigue limit = 324 MPa in GE database


EBM -TiAl Fatigue Properties, Haigh Diagram

Ref. TiAl, HCF test results @ 760°C

• All HCF data exceed GE reference data !


EBM -TiAl Fatigue Properties, turbine blades

HCF test with turbine blade geometries at RT


• Pre-oxidized 20 hrs at 650°C
• Machined by ECM to surface roughness Ra=1.6 m
• Average fatigue limit: 400 MPa (58 ksi)

700 Hz

crack
initiation
Summary and Conclusions

Core benefits of EBM additive manufacturing:


• Freedom in design
• Very low material waste
• Material properties compliant with standards
• Integrated lattice/cellular structures
• Proven productivity – in continuous serial production since 2007
• Large potential for new materials

Gamma Titanium Aluminide manufactured with EBM:


• 3D geometries (turbine blades) fabricated with proven process stability
• HIP eliminates residual porosity
• Complies with chemical spec. after 1% Al addition to powder
• Fine grain duplex microstructure after proper heat treatment
• Tensile properties equal to GE reference data
• HCF properties exceed GE reference data
• EBM serial production of -TiAl to be launched at AvioProp in Italy
Thank you!

Ulf Ackelid
Arcam AB
-TiAl with EBM
Creep properties

 Density corrected creep properties compared with Ni-base superalloys for use in
LPT’s last stages.
-TiAl with EBM
A2X Heat load optimization

 The standard Arcam A2 system is designed for


production in Ti6Al4V and CoCr.

 -TiAl requires substantially more heat than


titanium to be processed in the EBM.

 Higher temperatures to dissolve surface oxides

 The majority of heat is lost through radiation from


build area into subsystems.

 Heat load optimization needed to improve the


insulation to ensure correct operating temperatures of
subsystems.
-TiAl with EBM
A2X Heat load optimization
Build
temperature
°C

1100
TiAl Range
1050 A2X operating
1000 mode
950

750

700
Titanium range Arcam A2 normal
650 operating mode
600
-TiAl with EBM
A2X Heat load optimization

The heat load on critical components has been reduced to a minimum by optimizing
insulation and at the same time increasing the utilization of available beam power

─ Resulting in a customized A2 for serial


production of TiAl turbine blades
─ Build envelope:
─ 200 x 200 x 375 mm
─ With four systems delivered to Avio,
May 2010

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