Browsing by Author "Chehab, Bechir"

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    Effect of inter layer cold work on 2024 aluminium alloy produced by wire directed energy deposition
    (Elsevier, 2023-06-23) Eimer, Eloise; Ganguly, Supriyo; Czink, Steffen; Dietrich, Stefan; Chehab, Bechir; Ding, Jialuo; Williams, Stewart
    Aluminium copper magnesium alloys are widely used in the aerospace sector. Wire-based Directed Energy Deposition could replace conventional manufacturing routes to build large and semi-complex components for this industry if high mechanical performance can be achieved in the deposit. The scope of this study was to assess the effect of inter-pass rolling on a 2024 aluminium alloy wire-based DED built structure and to investigate the impact of cold work during the deposition process on the microstructure and mechanical performances. The 2024 aluminium alloy was deposited using two variants of gas metal arc process, and the effects of the deposition process, cold work and heat treatment were studied using macro and microstructural observations, hardness measurement and tensile tests. The material response to inter-pass rolling and the formation of rolling defects was found to depend on the deposition process variant and bead geometry. While a significant strengthening of the deposit was observed with one process, only a drastic reduction of defects was observed with the second. It was also found that the application of cold work and heat treatment led to lowering of anisotropy and higher ductility when compared with heat-treated deposit without any inter-pass rolling.
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    Effect of substrate alloy type on the microstructure of the substrate and deposited material interface in aluminium wire + arc additive manufacturing
    (MDPI, 2021-06-04) Eimer, Eloise; Williams, Stewart; Ding, Jialuo; Ganguly, Supriyo; Chehab, Bechir
    Wire + Arc Additive Manufacture is an Additive Manufacturing process that requires a substrate to initiate the deposition process. In order to reduce material waste, build and lead time, and improve process efficiency, it is desirable to include this substrate in the final part design. This approach is a valid option only if the interface between the substrate and the deposited metal properties conform to the design specifications. The effect of substrate type on the interface microstructure in an aluminium part was investigated. Microstructure and micro-hardness measurements show the effect of substrate alloy and temper on the interface between the substrate and deposited material. Microcracks in the as-deposited condition were only found in one substrate. The deposited material hardness is always lower than the substrate hardness. However, this difference can be minimised by heat treatment and even eliminated when the substrate and wire are made of the same alloy.
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    Mechanical performances of the interface between the substrate and deposited material in aluminium wire Direct Energy Deposition
    (Elsevier, 2023-01-06) Eimer, Eloise; Williams, Stewart; Ding, Jialuo; Ganguly, Supriyo; Chehab, Bechir
    Wire and Arc Additive manufacturing (WAAM) is a Direct Energy Deposition process suitable for the manufacture of large aluminium components. Additive Manufacturing can enable the production of functionally graded structure which could be done by integrating the substrate required to start the deposition into the final component. This paper aims to assess the possibility of including a substrate in a component by investigating the mechanical performances of the interface between a wrought plate and WAAM deposit. Four substrates alloys and 2319 WAAM alloy were investigated. Inter-layer rolling and heat treatment, process steps known for improving the properties of WAAM deposit, were implemented. Each interface was examined using microhardness profiles, tensile tests, post rupture fractography and microstructural analysis. The WAAM deposit hardness was lower than that of the substrate in the as-deposited condition. Although the interface had no impact when using the same alloy for both substrate and wire, the weakest point of the combination was at the interface in dissimilar alloy combination. Heat treatment reduced the properties difference between the substrate and WAAM deposit. Inter-pass rolling strengthen the WAAM deposit without impacting the substrate and eliminated the micro crack that occasionally formed in the fusion zone in the as-deposited condition.