Browsing by Author "Bhujangrao, Trunal"
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Item Effect of Heat Treatment on the Microstructure and Hardness of Ni-Based Alloy 718 in a Variable Thickness Geometry Deposited by Powder Fed Directed Energy Deposition(2022-05-31) Ramiro, Pedro; Galarraga, Haize; Pérez-Checa, Anabel; Ortiz, Mikel; Alberdi, Amaia; Bhujangrao, Trunal; Morales, Elena; Ukar, Eneko; Tecnalia Research & Innovation; FABRIC_INTEL; CIRMETAL; Caracterización y Validación. Materiales; Caracterización y Validación. MecánicosFeature addition to existing parts is a trending application for Directed Energy Deposition (DED) and can be used to add complex geometry features to basic forged geometries with the aim to reduce and simplify the number of processing steps as machining and assembling. However, the mechanical properties of as-deposited Inconel 718 fabricated by Powder-fed Directed Energy Deposition (Powder-fed DED) are far lower than the relevant specifications, making it necessary to apply different heat treatment with the purpose of improving deposited material performance. In addition, the effects of heat treatments in both variable thickness deposited geometry and forge substrate have not been studied. In this study, the effect of heat treatment within the Aerospace Materials Specifications (AMS) for cast and wrought Inconel 718 on the microstructure and hardness of both the Ni-Based Alloy 718 deposited geometry and substrate are analyzed in different parts of the geometry. The microstructure of all samples (as-deposited and heat-treated) is analyzed by Scanning Electron Microscope (SEM) and Energy Dispersive Spectrometer (EDS), confirming the formation of aluminum oxides and titanium nitrides and carbonitrides in the deposited structure.Item Effect of the Metal Transfer Mode on the Symmetry of Bead Geometry in WAAM Aluminum(2021-07-10) Veiga, Fernando; Suárez, Alfredo; Aldalur, Eider; Bhujangrao, Trunal; Tecnalia Research & Innovation; FABRIC_INTELThe symmetrical nature in the case of wall fabrication by wire arc additive manufacturing (WAAM) has been observed in the literature, but it has not been studied as a source of knowledge. This paper focuses on the comparative study of three drop transfer methods employing Gas Metal Arc Welding (GMAW) technology, one of the most reported for the manufacture of aluminum alloys. The transfer modes studied are the well-known pulsed GMAW, cold arc, and the newer pulsed AC. The novelty of the last transfer mode is the reversal of the polarity during the preparation phase of the substance for droplet deposition. This study compares the symmetry of zero beads to determine the best parameters and transfer modes for wire arc additive manufacturing of 5 series aluminum. The pulsed transfer modes show values of 0.6 for symmetry ratio, which makes them more interesting strategies than cold arc with a symmetry ratio of 0.5. Furthermore, the methodology proposed in this study can be extrapolated to other materials manufactured with this technology.Item High-Temperature Mechanical Properties of IN718 Alloy: Comparison of Additive Manufactured and Wrought Samples(Multidisciplinary Digital Publishing Institute (MDPI), 2020-08-09) Bhujangrao, Trunal; Veiga, Fernando; Suárez, Alfredo; Iriondo, Edurne; Mata, Franck GirotWire Arc Additive Manufacturing (WAAM) is one of the most appropriate additive manufacturing techniques for producing large-scale metal components with a high deposition rate and low cost. Recently, the manufacture of nickel-based alloy (IN718) using WAAM technology has received increased attention due to its wide application in industry. However, insufficient information is available on the mechanical properties of WAAM IN718 alloy, for example in high-temperature testing. In this paper, the mechanical properties of IN718 specimens manufactured by the WAAM technique have been investigated by tensile tests and hardness measurements. The specific comparison is also made with the wrought IN718 alloy, while the microstructure was assessed by scanning electron microscopy and X-ray diffraction analysis. Fractographic studies were carried out on the specimens to understand the fracture behaviour. It was shown that the yield strength and hardness of WAAM IN718 alloy is higher than that of the wrought alloy IN718, while the ultimate tensile strength of the WAAM alloys is difficult to assess at lower temperatures. The microstructure analysis shows the presence of precipitates (laves phase) in WAAM IN718 alloy. Finally, the effect of precipitation on the mechanical properties of the WAAM IN718 alloy was discussed in detail.Item Influence of Heat Input on the Formation of Laves Phases and Hot Cracking in Plasma Arc Welding (PAW) Additive Manufacturing of Inconel 718(2020-06) Artaza, Teresa; Bhujangrao, Trunal; Suárez, Alfredo; Veiga, Fernando; Lamikiz, Aitzol; FABRIC_INTEL; Tecnalia Research & InnovationNickel-based alloys have had extensive immersion in the manufacturing world in recent decades, especially in high added value sectors such as the aeronautical sector. Inconel 718 is the most widespread in terms of implantation. Therefore, the interest in adapting the manufacture of this material to additive manufacturing technologies is a significant objective within the scientific community. Among these technologies for the manufacture of parts by material deposition, plasma arc welding (PAW) has advantages derived from its simplicity for automation and integration on the work floor with high deposition ratios. These characteristics make it very economically appetizing. However, given the tendency of this material to form precipitates in its microstructure, its manufacturing by additive methods is very challenging. In this article, three deposition conditions are analyzed in which the energy and deposition ratio used are varied, and two cooling strategies are studied. The interpass cooling strategy (ICS) in which a fixed time is expected between passes and controlled overlay strategy (COS) in which the temperature at which the next welding pass starts is controlled. This COS strategy turns out to be advantageous from the point of view of the manufacturing time, but the deposition conditions must be correctly defined to avoid the formation of Laves phases and hot cracking in the final workpiece.Item Model for the Prediction of Deformations in the Manufacture of Thin-Walled Parts by Wire Arc Additive Manufacturing Technology(2021-04-21) Casuso, Mikel; Veiga, Fernando; Suárez, Alfredo; Bhujangrao, Trunal; Aldalur, Eider; Artaza, Teresa; Amondarain, Jaime; Lamikiz, Aitzol; FABRIC_INTEL; Tecnalia Research & InnovationGas Metal Arc Welding (GMAW) is a manufacturing technology included within the differentWire Arc Additive Manufacturing alternatives. These technologies have been generating great attention among scientists in recent decades. Its main qualities that make it highly productive with a large use of material with relatively inexpensive machine solutions make it a very advantageous technology. This paper covers the application of this technology for the manufacture of thin-walled parts. A finite element model is presented for estimating the deformations in this type of parts. This paper presents a simulation model that predicts temperatures with less than 5% error and deformations of the final part that, although quantitatively has errors of 20%, qualitatively allows to know the deformation modes of the part. Knowing the part areas subject to greater deformation may allow the future adaptation of deposition strategies or redesigns for their adaptation. These models are very useful both at a scientific and industrial level since when we find ourselves with a technology oriented to Near Net Shape (NNS) manufacturing where deformations are critical for obtaining the final part in a quality regime.Item Study of the Mechanical Behavior of Topologically Optimized Arc Wire Direct Energy Deposition Aerospace Fixtures(2022-02-24) Suárez, Alfredo; Veiga, Fernando; Bhujangrao, Trunal; Aldalur, Eider; FABRIC_INTEL; Tecnalia Research & InnovationThe reliability and performance qualification of additively manufactured metal parts is essential for their successful and safe use in engineering applications. Additive Manufacturing (AM) allows parts to be produced more easily than traditional manufacturing. Arc Wire Direct Energy Deposition (AW-DED) is one of the lesser-known metal additive manufacturing technologies. It has enormous potential for large-scale 3D printing applications in the aerospace industry. However, in the aerospace industry, one of the main challenges today is to reduce the weight of components without compromising their structural functionality. Topology optimization offers design engineers the opportunity to create lightweight and complex structural parts. In arc wire direct energy deposition (AW-DED) processes, processing parameters affect material microstructure features, overall part quality, and integrity, as well as bulk mechanical behavior. To address such challenges, the investigation presented in this paper describes a novel digital design approach combining topology optimization, process simulations, and size optimization of the tool components used in the aerospace industry to address effects caused during manufacturing by using Finite Element Modeling (FEM) simulations. This can lead to reduced costs, development time, material consumption, and product weight. Due to the flexibility mentioned above, parts designed for AM have the same structural load as conventional parts but with reduced mass and better part design. The results of this application are discussed in depth in this paper. This is a new research work with useful results and conclusions in the methodology for the evaluation of mechanical behavior of topologically optimized metal additive manufactured components. For this purpose, aerospace fixtures have been topologically designed by means of AW-DED-process-oriented techniques. Aerospace fixtures are normally used in the aerospace industry to support and hold various components. These new design paradigms make it possible to save on material costs oriented toward more sustainable and flexible manufacturing.Item Three-Dimensional Finite Element Modelling of Sheet Metal Forming for the Manufacture of Pipe Components: Symmetry Considerations: Symmetry Considerations(2022-01-25) Bhujangrao, Trunal; Veiga, Fernando; Penalva, Mariluz; Costas, Adriana; Ruiz, Cristina; Tecnalia Research & Innovation; FABRIC_INTELThe manufacture of parts by metal forming is a widespread technique in sectors such as oil and gas and automotives. It is therefore important to make a research effort to know the correct set of parameters that allow the manufacture of correct parts. This paper presents a process analysis by means of the finite element model. The use case presented in this paper is that of a 3-m diameter pipe component with a thickness of 22 mm. In this type of application, poor selection of process conditions can result in parts that are out of tolerance, both in dimensions and shape. A 3D finite element model is made, and the symmetry of the tube section generated in 2D is analysed. As a novelty, an analysis of the process correction as a function of the symmetrical deformation of the material in this case in the form of a pipe is carried out. The results show a correct fitting of the model and give guidelines for manufacturing.Item Validation of the Mechanical Behavior of an Aeronautical Fixing Turret Produced by a Design for Additive Manufacturing (DfAM)(2022-05-27) Veiga, Fernando; Bhujangrao, Trunal; Suárez, Alfredo; Aldalur, Eider; Goenaga, Igor; Gil-Hernandez, Daniel; Tecnalia Research & Innovation; FABRIC_INTEL; MAQUINAS; SMART_MONThe design of parts in such critical sectors as the manufacturing of aeronautical parts is awaiting a paradigm shift due to the introduction of additive manufacturing technologies. The manufacture of parts designed by means of the design-oriented additive manufacturing methodology (DfAM) has acquired great relevance in recent years. One of the major gaps in the application of these technologies is the lack of studies on the mechanical behavior of parts manufactured using this methodology. This paper focuses on the manufacture of a turret for the clamping of parts for the aeronautical industry. The design of the lightened turret by means of geometry optimization, the manufacture of the turret in polylactic acid (PLA) and 5XXX series aluminum alloy by means of Wire Arc Additive Manufacturing (WAAM) technology and the analysis by means of finite element analysis (FEA) with its validation by means of a tensile test are presented. The behavior of the part manufactured with both materials is compared. The conclusion allows to establish which are the limitations of the part manufactured in PLA for its orientation to the final application, whose advantages are its lower weight and cost. This paper is novel as it presents a holistic view that covers the process in an integrated way from the design and manufacture to the behaviour of the component in use