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  4. Avoiding cracks in multi-material printing by combining laser powder bed fusion with metallic foils: Application to Ti6Al4V-AlSi12 structures
 
research article

Avoiding cracks in multi-material printing by combining laser powder bed fusion with metallic foils: Application to Ti6Al4V-AlSi12 structures

Jamili, A. M.  
•
Jhabvala, J.  
•
Van Petegem, S.
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January 5, 2025
Additive Manufacturing

Laser powder bed fusion (LPBF) as an additive manufacturing (AM) technology has emerged as a powerful platform for producing multi-material metallic structures. The main drawbacks of using metallic powders for multi-material printing are related to technical issues (i.e. powder contamination reducing the reusability of the powder) and interfacial defects. This paper attempts to demonstrate the advantages of using a combination of metallic powders and thin foils for printing light titanium-aluminum multi-material structures. An AlSi12 powder was printed using the conventional LPBF process and the behavior of the second material feedstock was investigated using both Ti6Al4V powders and foils. The printing process was simulated numerically using a finite element model (FEM), and characterized experimentally through operando X-Ray diffraction (XRD). For the powder-powder combination, cracking near the interface between the two alloys was considered as a combined effect of residual stresses and the presence of brittle intermetallic compounds (IMCs); both were investigated using nanoindentation. Replacing the Ti6Al4V powder by a foil resulted in a thinner layer of Ti-Al IMCs near the interface, and eliminated the large interfacial cracks. The results from FEM and CALPHAD thermodynamic simulations, supported by operando XRD, indicated that the increased thermal conductivity of the foil, compared to powders, led to heat transfer within the foil and to the underlying LPBF structure, prior to local melting. The new thermal regime produced a flawless interface between Ti6Al4V and AlSi12, due to reduced residual stresses in the plane normal to the building direction, and lower volumes of brittle IMCs. It is concluded that using foils instead of powders mitigates cracking and enhances microstructures near the interface, due to changes in thermal regime and alloys mixing patterns.

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Type
research article
DOI
10.1016/j.addma.2024.104615
Scopus ID

2-s2.0-85212414776

Author(s)
Jamili, A. M.  

École Polytechnique Fédérale de Lausanne

Jhabvala, J.  

École Polytechnique Fédérale de Lausanne

Van Petegem, S.

Paul Scherrer Institut

Weisz-Patrault, D.

Laboratoire de Mecanique des Solides Ecole Polytechnique

Boillat, E.  

École Polytechnique Fédérale de Lausanne

Nohava, J.

Anton Paar GmbH

Özsoy, A.

École Polytechnique Fédérale de Lausanne

Banait, S.  

École Polytechnique Fédérale de Lausanne

Casati, N.

Paul Scherrer Institut

Logé, Roland E.  

École Polytechnique Fédérale de Lausanne

Date Issued

2025-01-05

Published in
Additive Manufacturing
Volume

97

Article Number

104615

Subjects

Aluminum

•

Laser Powder Bed Fusion

•

Light structures

•

Multi-material printing

•

Thin foils

•

Titanium

Editorial or Peer reviewed

REVIEWED

Written at

EPFL

EPFL units
LMTM  
FunderFunding(s)Grant NumberGrant URL

European Space Agency

20212101,4000143075

Available on Infoscience
January 25, 2025
Use this identifier to reference this record
https://infoscience.epfl.ch/handle/20.500.14299/244335
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