Engineering Papers⌕ Search

Engineering topics

Knapp, Cameron M.

Publications and source records attributed to Knapp, Cameron M..

Proton irradiation and characterization of additively manufactured 304L stainless steels

Irradiations were performed with 1.5 MeV protons to 0.6 dpa at 40–150 °C on additively manufactured (AM) 304L stainless steel and the changes in microstructure and mechanical behavior after irradiation were compared to wrought 304L stainless steel. Interestingly, all microstructural and hardness results after irradiation suggest the samples evolve toward a similar state, despite significant differences in the unirradiated microstructures and hardness values. A TEM and nanoindentation-based investigation of before and after proton irradiation at 40–150 °C is presented. Results are interpreted in terms of initial dislocation content, dislocation structures, and microstructural and chemical homogeneity.

36 MATERIALS SCIENCE↗

Additively manufactured tantalum microstructures

Additively manufacturing tantalum is a challenging process in which obstacles are stemming from the high melting temperature and susceptibility to oxidation of tantalum. In this paper, several combinations of deposition parameters were considered in an effort to obtain fully dense additively manufactured tantalum produced on an EOSINT M280 DMLS system. Deposition parameters significantly affect the resulting microstructure of additively manufactured tantalum, altering grain morphology, grain size, crystallographic preferred orientation, and deposition porosity. Due to the nature of the laser sintering process applied, which implies large directional temperature gradients, the resulting microstructures were strongly columnar along the building direction. Microstructural differences for different deposition conditions manifested themselves in both grain morphology and preferred crystal orientations in the columnar grains. Deposition speed and laser power were important parameters to consider for obtaining porosity-free material. Finally, stripe width had the most significant effect on grain growth.

36 MATERIALS SCIENCE↗

Impact of Defects in Powder Feedstock Materials on Microstructure of 304L and 316L Stainless Steel Produced by Additive Manufacturing

Recent work in both 304L and 316L stainless steel produced by additive manufacturing (AM) has shown that in addition to the unique, characteristic microstructures formed during the process, a fine dispersion of sub-micron particles, with a chemistry different from either the powder feedstock or the expected final material, are evident in the final microstructure. Such fine-scale features can only be resolved using transmission electron microscopy (TEM) or similar techniques. The present paper uses electron microscopy to study both the initial powder feedstock and microstructures in final AM parts. Special attention is paid to the chemistry and origin of these nanoscale particles in several different metal alloys, and their impact on the final build. Finally, comparisons to traditional, wrought material will be made.

36 MATERIALS SCIENCE↗

Spatially resolved texture and microstructure evolution of additively manufactured and gas gun deformed 304L stainless steel investigated by neutron diffraction and electron backscatter diffraction

In this study, we report the characterization of a 304L stainless steel cylindrical projectile produced by additive manufacturing. The projectile was compressively deformed using a Taylor Anvil Gas Gun, leading to a huge strain gradient along the axis of the deformed cylinder. Spatially resolved neutron diffraction measurements on the HIgh Pressure Preferred Orientation time-of-flight diffractometer (HIPPO) and Spectrometer for Materials Research at Temperature and Stress diffractometer (SMARTS) beamlines at the Los Alamos Neutron Science CEnter (LANSCE) with Rietveld and single-peak analysis were used to quantitatively evaluate the volume fractions of the α, γ, and ε phases as well as residual strain and texture. The texture of the γ phase is consistent with uniaxial compression, while the α texture can be explained by the Kurdjumov–Sachs relationship from the γ texture after deformation. This indicates that the material first deformed in the γ phase and subsequently transformed at larger strains. The ε phase was only found in volumes close to the undeformed material with a texture connected to the γ texture by the Shoji–Nishiyama orientation relationship. This allows us to conclude that the ε phase occurs as an intermediate phase at lower strain, and is superseded by the α phase when strain increases further. Furthe, we found a proportionality between the root-mean-squared microstrain of the γ phase, dominated by the dislocation density, with the α volume fraction, consistent with strain-induced martensite α formation. In conclusion, knowledge of the sample volume with the ε phase from the neutron diffraction analysis allowed us to identify the ε phase by electron back scatter diffraction analysis, complementing the neutron diffraction analysis with characterization on the grain level.

304L stainless steel↗

L2 Milestone 5433: Characterization of Dynamic Behavior of AM and Conventionally Processed Stainless Steel (316L and 304L)

For additive manufacturing (AM) of metallic materials, the certification and qualification paradigm needs to evolve as there currently exists no broadly accepted “ASTM- or DIN-type” additive manufacturing certified process or AM-material produced specifications. Accordingly, design, manufacture, and thereafter implementation and insertion of AM materials to meet engineering applications requires detailed quantification of the constitutive (strength and damage) properties of these evolving materials, across the spectrum of metallic AM methods, in comparison/contrast to conventionally-manufactured metals and alloys. This report summarizes the 316L SS research results and presents initial results of the follow-on study of 304L SS. For the AM-316L SS investigation, cylindrical samples of 316L SS were produced using a LENS MR-7 laser additive manufacturing system from Optomec (Albuquerque, NM) equipped with a 1kW Yb-fiber laser. The microstructure of the AM-316L SS was characterized in both the “as-built” Additively Manufactured state and following a heat-treatment designed to obtain full recrystallization to facilitate comparison with annealed wrought 316L SS. The dynamic shock-loading-induced damage evolution and failure response of all three 316L SS materials was quantified using flyer-plate impact driven spallation experiments at peak stresses of 4.5 and 6.35 GPa. The results of these studies are reported in detail in the first section of the report. Publication of the 316L SS results in an archival journal is planned. Following on from the 316L SS completed work, initial results on a study of AM 304L SS are in progress and presented herein. Preliminary results on the structure/dynamic spallation property behavior of AM-304L SS fabricated using both the directed-energy LENS and an EOS powder-bed AM techniques in comparison to wrought 304L SS is detailed in this Level 2 Milestone report.

316L SS↗

Laser Engineered Net Shaping Process Characterization

The thermo-mechanical characterization of additive manufacturing, specifically the Laser Engineered Net Shaping (LENS) process has become a priority research area at Los Alamos National Laboratory. The first study on LENS conducted at LANL is being conducted as collaboration between LANL and the University of Texas at Austin as research for a master’s thesis. This project takes a unique two path approach that merges both experimental and computational data in an attempt to gain further broad spectrum process knowledge of direct laser deposition as a means of additive manufacturing.

36 MATERIALS SCIENCE↗