Date of Award
Master of Science (MS)
Laminated metals., Manufacturing processes., Three-dimensional printing.
To reduce costs associated with the fabrication of low volume, complex components in many industries, use of additive manufacturing (AM) processes are being explored. This approach greatly reduces the time and cost by eliminating multiple processing steps, such as brazing and welding, to fabricate the component in one process. While processes such as powder bed fusion (PBF) can print monolithic components, directed energy deposition (DED) methods are used to print components using a combination of materials. DED processes, using either a blown powder or wire feedstock, can interchange materials for deposition of bimetallic combinations. One application for DED processing is in high heat flux applications that require materials with high thermal conductivity such as Cu based alloys to work in conjunction with a higher strength-lower density material such as Inconel for structural stability. While DED processes are being developed, little is known about the reliability and stability of the resulting interface formed as the metals are directly deposited onto one another. This study quantifies the mechanical properties of a bimetallic interface formed using two different DED processes and evaluates its stability at elevated temperatures. Specimens used in this study were fabricated by three different vendors using the two different DED processes distinguished by the feedstock. By fabricating miniature tensile specimens out of as-built components, the study found that blown powder DED provides a more consistent and stronger interface across the temperature ranges investigated.
Terrell, Jordan, "Quantifying bimetallic interfaces fabricated using directed energy deposition (DED) processes" (2020). Theses. 332.