Abnormal interfacial bonding mechanisms of multi-material additive-manufactured tungsten–stainless steel sandwich structure

Chao Wei; Heng Gu; Yuchen Gu; Luchao Liu; Yihe Huang; Dongxu Cheng; Zhaoqing Li; Lin Li

doi:10.1088/2631-7990/ac5f10

Tungsten (W) and stainless steel (SS) are well known for the high melting point and good corrosion resistance respectively. Bimetallic W–SS structures would offer potential applications in extreme environments. In this study, a SS→W→SS sandwich structure is fabricated via a special laser powder bed fusion (LPBF) method based on an ultrasonic-assisted powder deposition mechanism. Material characterization of the SS→W interface and W→SS interface was conducted, including microstructure, element distribution, phase distribution, and nano-hardness. A coupled modelling method, combining computational fluid dynamics modelling with discrete element method, simulated the melt pool dynamics and solidification at the material interfaces. The study shows that the interface bonding of SS→W (SS printed on W) is the combined effect of solid-state diffusion with different elemental diffusion rates and grain boundary diffusion. The keyhole mode of the melt pool at the W→SS (W printed on SS) interface makes the pre-printed SS layers repeatedly remelted, causing the liquid W to flow into the sub-surface of the pre-printed SS through the keyhole cavities realizing the bonding of the W→SS interface. The above interfacial bonding behaviours are significantly different from the previously reported bonding mechanism based on the melt pool convection during multiple material LPBF. The abnormal material interfacial bonding behaviours are reported for the first time.

HTML

Reference (65)

Zhang J, Luo L M, Zhu X Y, Chen H Y, Chen J L, Zan X, Cheng J G and Wu Y C 2015 Effect of doped Lu₂O₃ on the microstructures and properties of tungsten alloy prepared by spark plasma sintering J. Nucl. Mater. 456 316–20

S¸ahin Y 2014 Recent progress in processing of tungsten heavy alloys J. Powder Technol. 2014 764306

Waseem O A and Ryu H J 2016 Tungsten-based composites for nuclear fusion applications Nuclear Material Performance ed R A Rahman (London: IntechOpen) (https://doi.org/10.5772/62434)

Senthilnathan N, Annamalai A R and Venkatachalam G 2018 Microstructure and mechanical properties of spark plasma sintered tungsten heavy alloys Mater. Sci. Eng. A 710 66–73

Zu Y S and Lin S T 1997 Optimizing the mechanical properties of injection molded W4.9%Ni2.1%Fe in debinding J. Mater. Process. Technol. 71 337–42

Iveković A, Montero-Sistiaga M L, Vanmeensel K, Kruth J-P and Vleugels J 2019 Effect of processing parameters on microstructure and properties of tungsten heavy alloys fabricated by SLM Int. J. Refract. Met. Hard Mater. 82 23–30

Bose A et al 2018 Traditional and additive manufacturing of a new Tungsten heavy alloy alternative Int. J. Refract. Met. Hard Mater. 73 22–28

Cai Q S, Liu W S, Ma Y Z and Liu H Y 2015 Microstructure, residual stresses and mechanical properties of diffusion bonded tungsten-steel joint using a V/Cu composite barrier interlayer Int. J. Refract. Met. Hard Mater. 48 312–7

Park J Y, Jung Y I, Choi B K, Lee D W and Cho S 2013 Joining of tungsten to ferritic/martensitic steels by hot isostatic pressing J. Nucl. Mater. 442 S541–5

Wei C, Li L, Zhang X Y and Chueh Y-H 2018 3D printing of multiple metallic materials via modified selective laser melting CIRP Ann. 67 245–8

Chadha K, Tian Y, Pasco J and Aranas C Jr 2021 Dual-metal laser powder bed fusion of iron- and cobalt-based alloys Mater. Charact. 178 111285

Goh G L, Zhang H N, Chong T H and Yeong W Y 2021 3D printing of multilayered and multimaterial electronics: a review Adv. Electron. Mater. 7 2100445

Wei C and Li L 2021 Recent progress and scientific challenges in multi-material additive manufacturing via laser-based powder bed fusion Virtual Phys. Prototyp. 16 347–71

Wei C, Zhang Z Z, Cheng D X, Sun Z, Zhu M H and Li L 2021 An overview of laser-based multiple metallic material additive manufacturing: from macro- to micro-scales Int. J. Extrem. Manuf. 3 012003

Tan C L, Zhou K S and Kuang T C 2019 Selective laser melting of tungsten-copper functionally graded material Mater. Lett. 237 328–31

Wei C, Sun Z, Chen Q, Liu Z and Li L 2019 Additive manufacturing of horizontal and 3D functionally graded 316L/Cu10Sn components via multiple material selective laser melting J. Manuf. Sci. Eng. 141 081014

Wang D Z, Yu C F, Zhou X, Ma J, Liu W and Shen Z J 2017 Dense pure tungsten fabricated by selective laser melting Appl. Sci. 7 430

Field A C, Carter L N, Adkins N J E, Attallah M M, Gorley M J and Strangwood M 2020 The effect of powder characteristics on build quality of high-purity tungsten produced via laser powder bed fusion (LPBF) Metall. Mater. Trans. A 51 1367–78

Iveković A, Omidvari N, Vrancken B, Lietaert K, Thijs L, Vanmeensel K, Vleugels J and Kruth J-P 2018 Selective laser melting of tungsten and tungsten alloys Int. J. Refract. Met. Hard Mater. 72 27–32

Casati R, Lemke J and Vedani M 2016 Microstructure and fracture behavior of 316L austenitic stainless steel produced by selective laser melting J. Mater. Sci. Technol. 32 738–44

Chen K Y, Wang C, Hong Q F, Wen S F, Zhou Y, Yan C Z and Shi Y S 2020 Selective laser melting 316L/CuSn10 multi-materials: processing optimization, interfacial characterization and mechanical property J. Mater. Process. Technol. 283 116701

Wang D, Song C H, Yang Y Q and Bai Y C 2016 Investigation of crystal growth mechanism during selective laser melting and mechanical property characterization of 316L stainless steel parts Mater. Des. 100 291–9

Chen J, Yang Y Q, Song C H, Zhang M K, Wu S B and Wang D 2019 Interfacial microstructure and mechanical properties of 316L/CuSn10 multi-material bimetallic structure fabricated by selective laser melting Mater. Sci. Eng. A 752 75–85

Caiazzo F, Alfieri V and Casalino G 2020 On the relevance of volumetric energy density in the investigation of Inconel 718 laser powder bed fusion Materials 13 538

Gu H, Wei C, Li L, Ryan M, Setchi R, Han Q Q and Qian L L 2021 Numerical and experimental study of molten pool behaviour and defect formation in multi-material and functionally graded materials laser powder bed fusion Adv. Powder Technol. 32 4303–21

Gu H, Wei C, Li L, Han Q Q, Setchi R, Ryan M and Li Q 2020 Multi-physics modelling of molten pool development and track formation in multi-track, multi-layer and multi-material selective laser melting Int. J. Heat Mass Transfer 151 119458

Tang C, Tan J L and Wong C H 2018 A numerical investigation on the physical mechanisms of single track defects in selective laser melting Int. J. Heat Mass Transfer 126 957–68

Tolias P and The EUROfusion MST1 Team 2017 Analytical expressions for thermophysical properties of solid and liquid tungsten relevant for fusion applications Nucl. Mater. Energy 13 42–57

Yan X L, Pang J C and Jing Y L 2019 Ultrasonic measurement of stress in SLM 316L stainless steel forming parts manufactured using different scanning strategies Materials 12 2719

Brytan Z 2017 Comparison of vacuum sintered and selective laser melted steel AISI 316L Arch. Metall. Mater. 62 2125–31

Vrancken B, Thijs L, Kruth J P and Van Humbeeck J 2014 Microstructure and mechanical properties of a novel β titanium metallic composite by selective laser melting Acta Mater. 68 150–8

Tan C L, Zhou K S, Ma W Y, Attard B, Zhang P P and Kuang T C 2018 Selective laser melting of high-performance pure tungsten: parameter design, densification behavior and mechanical properties Sci. Technol. Adv. Mater. 19 370–80

Razavykia A, Brusa E, Delprete C and Yavari R 2020 An overview of additive manufacturing technologies—a review to technical synthesis in numerical study of selective laser melting Materials 13 3895

Shinjo J and Panwisawas C 2021 Digital materials design by thermal-fluid science for multi-metal additive manufacturing Acta Mater. 210 116825

Chen Y H, Clark S J, Leung C L A, Sinclair L, Marussi S, Olbinado M P, Boller E, Rack A, Todd I and Lee P D 2020 In-situ synchrotron imaging of keyhole mode multi-layer laser powder bed fusion additive manufacturing Appl. Mater. Today 20 100650

Davidzon M I 2012 Newton’s law of cooling and its interpretation Int. J. Heat Mass Transfer 55 5397–402

de Macedo H R, da Silva A G P and de Melo D M A 2003 The spreading of cobalt, nickel and iron on tungsten carbide and the first stage of hard metal sintering Mater. Lett. 57 3924–32

Zhao X, Xu S and Liu J 2017 Surface tension of liquid metal: role, mechanism and application Front. Energy 11 535–67

Hengsbach F et al 2018 Inline additively manufactured functionally graded multi-materials: microstructural and mechanical characterization of 316L parts with H13 layers Prog. Addit. Manuf. 3 221–31

Paul A 2013 A pseudobinary approach to study interdiffusion and the Kirkendall effect in multicomponent systems Phil. Mag. 93 2297–315

Chen X X, Shen J, Kecskes L J and Wei Q 2020 Tungsten-based heterogeneous multilayer structures via diffusion bonding Int. J. Refract. Met. Hard Mater. 92 105308

Rahman A H M E and Cavalli M N 2012 Diffusion bonding of commercially pure Ni using Cu interlayer Mater. Charact. 69 90–96

Muster W J, Yoon D N and Huppmann W J 1979 Solubility and volume diffusion of nickel in tungsten at 1640 ℃ J. Less-Common Met. 65 211–6

Reisner M, Oberkofler M, Elgeti S, Balden M, Höschen T, Mayer M and Silva T F 2019 Interdiffusion and phase formation at iron-tungsten interfaces Nucl. Mater. Energy 19 189–94

Mehrer H 2007 Continuum theory of diffusion Diffusion in Solids: Fundamentals, Methods, Materials, Diffusion-Controlled Processes ed H Mehrer (Berlin: Springer) pp 27–36

Fang T T, Chen M I and Hsu W D 2020 Insight into understanding the jump frequency of diffusion in solids AIP Adv. 10 065132

Yusuf S M, Choo E and Gao N 2020 Comparison between virgin and recycled 316L SS and AlSi₁₀Mg powders used for laser powder bed fusion additive manufacturing Metals 10 1625

Malizia A, Rossi R and Cacciotti I 2018 Improvement of the shadow tracking setup as a method to measure the velocities values of dark dust in order to reduce the risks of radioactive releases or explosions Rev. Sci. Instrum. 89 083306

Giannattasio A, Yao Z, Tarleton E and Roberts S G 2010 Brittle–ductile transitions in polycrystalline tungsten Phil. Mag. 90 3947–59

Van Uffelen P and Suzuki M 2012 Oxide fuel performance modeling and simulations Comp. Nucl. Mater. 3 535–77

Gietzelt T, Toth V and Huell A 2016 Diffusion bonding: influence of process parameters and material microstructure Joining Technologies ed M Ishak (London: IntechOpen) pp 196–212

Zhang Y W, Li S J, Hao Y L and Yang R 2010 Nanoindentation study on Ti-24Nb-4Zr-8Sn single crystals Chin. J. Nonferrous Met. 20 528–32

Cobbinah P V, Nzeukou R A, Onawale O T and Matizamhuka W R 2021 Laser powder bed fusion of potential superalloys: a review Metals 11 58

Jung B B, Lee H K and Park H C 2013 Effect of grain size on the indentation hardness for polycrystalline materials by the modified strain gradient theory Int. J. Solids Struct. 50 2719–24

Ward L, Junge F, Lampka A, Dobbertin M, Mewes C and Wienecke M 2014 The effect of bias voltage and gas pressure on the structure, adhesion and wear behavior of diamond like carbon (DLC) coatings with Si interlayers Coatings 4 214–30

Huang H, Wu Y Q, Wang S L, He Y H, Zou J, Huang B Y and Liu C T 2009 Mechanical properties of single crystal tungsten microwhiskers characterized by nanoindentation Mater. Sci. Eng. A 523 193–8

Bayat M, Thanki A, Mohanty S, Witvrouw A, Yang S F, Thorborg J, Tiedje N S and Hattel J H 2019 Keyhole-induced porosities in laser-based powder bed fusion (L-PBF) of Ti₆Al₄V: high-fidelity modelling and experimental validation Addit. Manuf. 30 100835

Yao L M, Huang S, Ramamurty U and Xiao Z M 2021 On the formation of ‘Fish-scale’ morphology with curved grain interfacial microstructures during selective laser melting of dissimilar alloys Acta Mater. 220 117331

Radovic Z, Jaukovic N, Lalovic M and Tadic N 2008 Positive segregation as a function of buoyancy force during steel ingot solidification Sci. Technol. Adv. Mater. 9 045003

Marcus Y 2017 On the compressibility of liquid metals J. Chem. Thermodyn. 109 11–15

Jain S C and Willander S 2003 Strain, growth, and TED in SiGeC layers Silicon-germanium Strained Layers and Heterostructures ed S C Jain and S Willander (New York: Academic) pp 61–90

Yu H-C, Van der Ven A and Thornton K 2008 Theory of grain boundary diffusion induced by the Kirkendall effect Appl. Phys. Lett. 93 091908

Jaseliunaite J and Galdikas A 2020 Kinetic modeling of grain boundary diffusion: the influence of grain size and surface processes Materials 13 1051

Yin J, Zhang W Q, Ke L D, Wei H L, Wang D Z, Yang L L, Zhu H H, Dong P, Wang G Q and Zeng X Y 2021 Vaporization of alloying elements and explosion behavior during laser powder bed fusion of Cu–10Zn alloy Int. J. Mach. Tools Manuf. 161 103686

Zhang W Q, Zhang B P, Xiao H F, Yang H Q, Wang Y and Zhu H H 2021 A layer-dependent analytical model for printability assessment of additive manufacturing copper/steel multi-material components by directed energy deposition Micromachines 12 1394

Abnormal interfacial bonding mechanisms of multi-material additive-manufactured tungsten–stainless steel sandwich structure

doi: 10.1088/2631-7990/ac5f10

Abstract

Keywords

通讯作者: 陈斌, bchen63@163.com

Article Metrics