Publications

Abstract not provided.

ATP-5 aluminum alloy was considered as an alternative to 6061-T651 aluminum alloy to minimize machining distortion. ATP-5 is a proprietary cast alloy that is compositionally similar to 5083 aluminum and is purported to have excellent machinability, stability, and corrosion response. Dimensional stability tests, mechanical testing, chemical analysis, microstructural analysis, and fractography were completed to understand the metallurgy of the ATP-5 alloy and assess its potential as a 6061-T651 alloy alternative. Ultimately, the ATP-5 was found to retain dimensional stability issues, albeit to a lesser extent, relative to the 6061-T651 alloy. Combined with the residual cast structure observed microstructurally and lot-to-lot mechanical property variation, the alloy was deemed not suitable for a structural application. Alternative uses of ATP-5 include tooling, molds, vacuum chucks, fixtures, and jigs, where the material can shine in non-load bearing applications with a need for dimensional control and machinability.

Metallic additive manufacturing (AM) provides a customizable and tailorable manufacturing process for new engineering designs and technologies. The greatest challenge currently facing metallic AM is maintaining control of microstructural evolution during solidification and any solid state phase transformations during the build process. Ti-6Al-4V has been extensively surveyed in this regard, with the potential solid state and solidification microstructures explored at length. This work evaluates the applicability of previously determined crystallographic markers of microstructural condition observed in electron beam melting powder bed fusion (PBF-EB) builds of Ti-6Al-4V in a directed energy deposition (DED) build process. The aim of this effort is to elucidate whether or not these specific crystallographic textures are useful tools for indicating microstructural conditions in AM variants beyond PBF-EB. Parent β-Ti grain size was determined to be directly related to α-Ti textures in the DED build process, and the solid state microstructural condition could be inferred from the intensity of specific α-Ti orientations. Qualitative trends on the as-solidified β-Ti grain size were also determined to be related to the presence of a fiber texture, and proposed as a marker for as-solidified grain size in any cubic metal melted by AM. Analysis of the DED Ti-6Al-4V build also demonstrated a near complete fracture of the build volume, suspected to originate from accumulated thermal stresses in the solid state. Crack propagation was found to only appreciably occur in regions of slow cooling with large α+β colonies. Schmid factors for the basal and prismatic α-Ti systems explained the observed crack pathway, including slower bifurcation in colonies with lower Schmid factors of both slip systems. Colony morphologies and localized equiaxed β-Ti solidification were also found to originate from build pauses during production and uneven heating of the build edges during deposition. Tailoring of DED Ti-6Al-4V microstructures with the insight gained here is proposed, along with cautionary insight on preventing unplanned build pauses to maintain an informed and controlled thermal environment for microstructural control.

Abstract not provided.

Abstract not provided.

Incipient melting is a phenomenon that can occur in aluminum alloys where solute rich areas, such as grain boundaries, can melt before the rest of the material; incipient melting can degrade mechanical and corrosion properties and is irreversible, resulting in material scrapping. After detecting indications of incipient melting as the cause of failure in 7075 aluminum alloy parts (AA7075), a study was launched to determine threshold temperature for incipient melting. Samples of AA7075 were solution annealed using temperatures ranging from 870-1090F. A hardness profile was developed to demonstrate the loss of mechanical properties through the progression of incipient melting. Additionally, Zeiss software Zen Core Intellesis was utilized to more accurately quantify the changes in microstructural properties as AA7075 surpassed the onset of incipient melting. The results from this study were compared with previous AA7075 material that demonstrated incipient melting.