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Металлургические характеристики деталей из сплава Co-Cr-Mo, полученных по гибридной технологии
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P. Ferro , A. Fabrizi , G. Savio , R. Meneghello , F. Berto
1 Университет Падуи, Виченца, 36100, Италия 2 Университет Падуи, Падуя, 35131, Италия 3 Норвежский университет естественных и технических наук, Тронхейм, 7491, Норвегия
Технология аддитивного производства открывает новые невероятные возможности в проектировании деталей. В настоящее время оценка конструкционной прочности деталей, изготовленных аддитивным способом, представляет собой сложную задачу, решение которой позволит вывести аддитивные детали на рынок. Одним из основных недостатков аддитивного производства является низкое качество поверхностей и большой размерный допуск выращенных изделий. Решением в данной ситуации может стать гибридное производство, объединяющее субтрактивный и аддитивный методы. Гибридное производство, требующее меньших финансовых и временных затрат, заслуживает изучения с точки зрения возможных применений. Целью настоящей работы является оценка микроструктурных свойств гибридных образцов сплава Co-Cr-Mo, в которых аддитивная часть выращивается на механически обработанной части. Результаты показали отличное металлургическое сцепление между двумя деталями, обработанными по-разному.
Ключевые слова: селективное лазерное сплавление, сплав Co-Cr-Mo, гибридное производство, микроструктура, механические свойства, биоматериалы
DOI 10.24412/1683-805X-2021-6-65-69
Metallurgical characterization of Co-Cr-Mo parts processed by hybrid manufacturing technology
P. Ferro1, A. Fabrizi1, G. Savio2, R. Meneghello1, and F. Berto3
1 Department of Engineering and Management, University of Padova, Vicenza, 36100, Italy
2 Department of Civil, Environmental and Architectural Engineering, Padova, 35131, Italy
3 Department of Mechanical and Industrial Engineering, Norwegian University of Science and Technology,
Trondheim, 7491, Norway
Additive manufacturing technology offers new and incredible opportunities in design of components. Nowadays, structural integrity assessment of additively manufactured components is a formidable challenge that needs to be faced out in order to allow such components to be launched in the market. One of the major drawbacks of additive manufacturing processes is the low surface finishing and geometrical tolerance of the built parts. In this scenario, hybrid manufacturing, which takes advantage of both subtractive and additive manufacturing, can be considered a solution worthy of investigation in view of possible applications, saving costs and time in component production. The present work is aimed at assessing the microstructural properties of subtractively/additively Co-Cr-Mo hybrid manufactured samples, where the additive part is built over the machined one. Results showed an excellent metallurgical coupling at the interface between the two differently processed parts.
Keywords: selective laser melting, Co-Cr-Mo alloy, hybrid manufacturing, microstructure, mechanical properties, bio-materials
© Ferro P., Fabrizi A., Savio G., Meneghello R., Berto F., 2021
1. Introduction
In last years additive manufacturing (AM) technologies applied to metallic materials experienced a formidable breakthrough both in the industrial sector with the production of complex structural parts and in the scientific as well as academic sector where the challenges were, and still are, to find new suitable-to-process alloys [1-3], develop process parameters optimization criteria [4, 5], assure structural integrity of the parts [6-11], re-design components with the aim of reducing their weights. It is worth mentioning the numerous advantages of these technologies, say selective laser melting (SLM), electron beam melting (EBM) or binder jetting (BJG), compared to standard subtractive methodologies: (i) a complete freedom in components shape design, (ii) less production of scraps, (iii) shorter time to market, (iv) more customization opportunities. Considering the possibility of reducing weight of the parts and saving material, AM can be classified as a green technology, as well. However, there are even disadvantages. Among these, probably the most important are: high residual stress, poor dimensional accuracy and surface finish, high initial costs and time consuming for process parameters optimization. The low productivity could also be a drawback when considering SLM process [12]. As a matter of fact, using optimum process parameters and a 40 ^m layer thickness, the volumetric deposition rate performed by SLM of maraging steel using an EOS M290 machine is 10.8 cm3/h [13, 14].
In this regard, conventional subtractive manufacturing technologies are irreplaceable and even strategic if used in synergic combination with additive techniques. Additive/subtractive hybrid manufacturing (A/SM) of metallic parts was introduced in 1998 with the pioneering work of Kruth et al. [15] who used CNC (computer numerical control) milling operation to remedy the relative inaccuracy of each powder jet deposition during the component building. It is needed to point out that when dealing with hybrid manufacturing, one can refers to the use of subtractive techniques, say milling, used in-parallel to the additive techniques in order to adjust the tolerance and roughness of the part while building the whole component itself [16-18], as well as the use of subtractive techniques, say turning, to produce first a portion of the component that needs high dimensional tolerances and then additive techniques to build, in-series, the remaining part of the component that does not require high surface finishing (that is
the case studied in the present work). This last in-series procedure is relative recent in the panorama of the powder-bed fusion (PBF) technologies and it is obviously much different from the standard use of finishing processes applied to an already built additive part. Among the main advantages in using hybrid systems there are: the repair of currently existing high-value components, the high surface finishing of external and internal parts of complex shape, the precision guaranteed by the possibility of printing and milling the part in the same reference coordinate system, the improved fatigue strength induced by high surface finishing of components [19], improved productivity and finally multi-material 3D printing [20]. For a short review of hybrid additive systems, the readers can refer to [21].
Hybrid manufacturing processes pose a significant technological advance, allowing for component repairs [22-25], production of bi-materials [26-30], manufacturing of large components with intricate designs [31-35] as well as the improvement of components productivity and performances [36-40].
Marklein et al. [37], in their recent work, described the manufacturing of a gear component with discrete tooth geometry by powder bed fusion of metal using a laser beam and forming. They found that tooth geometry manufactured by additive manufacturing and forming is closer to the target than for the conventional process chain. In their recent work, Do-lev et al. [38] examined in detail the tensile behaviour and fracture toughness of a hybrid Ti-6Al-4V alloy. Compact tension and uniaxial tension specimens extracted from the hybrid pre-forms demonstrated good fracture and properties with no preference for crack growth in neither the AM nor wrought materials. In another work [39], the impact of process parameters on relative density, warpage and bonding strength between sheet metal and additively manufactured element were studied. Meiners et al. [40] investigated the use of powder laser metal deposition (p-LMD) and wire-arc additive manufacturing (WAAM) for hybrid manufacturing of Ti-6Al-4V aerospace forgings. The proposed manufacturing route is based on a conventionally pre-formed forging, which does not yet have all the features of the final component. These features, such as ribs or other structural or functional geometries, will be added by additive manufacturing. In this way, the number of processing steps and forging dies are reduced, and efficient near-net-shape production could be provided.
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Received 12.05.2021, revised 03.06.2021, accepted 03.06.2021
This is an excerpt of the article "Metallurgical Characterization of Co-Cr-Mo Parts Processed by Hybrid Manufacturing Technology". Full text of the paper is published in Physical Mesomechanics Journal. DOI: 10.1134/S1029959922020072
Сведения об авторах
Paolo Ferro, Prof., University of Padova, Italy, [email protected]
Alberto Fabrizi, Prof., University of Padova, Italy, [email protected]
Gianpaolo Savio, Assist. Prof., University of Padova, Italy, [email protected]
Roberto Meneghello, Prof., University of Padova, Italy, [email protected]
Filippo Berto, Prof., Norwegian University of Science and Technology, Norway, [email protected]
