J. Mater. Sci. Technol. ›› 2021, Vol. 67: 80-94.DOI: 10.1016/j.jmst.2020.04.085
• Research article • Previous Articles Next Articles
A.N.M. Tanvira, Md. R.U. Ahsana, Gijeong Seob, Brian Batesc, Chanho Leed, Peter K. Liawd, Mark Noakese, Andrzej Nycze, Changwook Jif, Duck Bong Kimb,*()
Received:
2020-02-04
Revised:
2020-04-07
Accepted:
2020-04-24
Published:
2021-03-20
Online:
2021-04-15
Contact:
Duck Bong Kim
About author:
* E-mail address: dkim@tntech.edu (D.B. Kim).A.N.M. Tanvir, Md. R.U. Ahsan, Gijeong Seo, Brian Bates, Chanho Lee, Peter K. Liaw, Mark Noakes, Andrzej Nycz, Changwook Ji, Duck Bong Kim. Phase stability and mechanical properties of wire + arc additively manufactured H13 tool steel at elevated temperatures[J]. J. Mater. Sci. Technol., 2021, 67: 80-94.
Fig. 1. Experimental setup: (a) wire + arc additive manufacturing (WAAM) system setup, (b) deposition pattern: red - odd number layers and blue - even number layers, and (c) final deposited part.
Unit | Value | ||
---|---|---|---|
Process parameters | Voltage | V | 17.8 |
Ampere | A | 205 | |
Single-layer width | mm | 6-7 | |
Single-layer thickness | mm | 3.5 | |
Bead overlap | mm | 50 % (approximate) | |
x and y offset | mm | 3.5 | |
z offset | mm | 3 | |
Moving speed | cm/min | 80 | |
Torch angle | Degree | 90° | |
Material | Wire feed rate | m/min | 6.5 |
Diameter | mm | 1.2 | |
Inert gas type | - | 75 % Ar + 25 % CO2 | |
Manufacturing environment | Inert gas flow rate | L/min | 12 |
Intermediate temperature | °C | 200 | |
Total layers deposited | - | 20 |
Table 1 Process parameters for fabricating the H13 tool steel solid block.
Unit | Value | ||
---|---|---|---|
Process parameters | Voltage | V | 17.8 |
Ampere | A | 205 | |
Single-layer width | mm | 6-7 | |
Single-layer thickness | mm | 3.5 | |
Bead overlap | mm | 50 % (approximate) | |
x and y offset | mm | 3.5 | |
z offset | mm | 3 | |
Moving speed | cm/min | 80 | |
Torch angle | Degree | 90° | |
Material | Wire feed rate | m/min | 6.5 |
Diameter | mm | 1.2 | |
Inert gas type | - | 75 % Ar + 25 % CO2 | |
Manufacturing environment | Inert gas flow rate | L/min | 12 |
Intermediate temperature | °C | 200 | |
Total layers deposited | - | 20 |
Fig. 3. Optical microstructure of AISI H13 tool steel. (a)-(c) Micrographs using a light etchant, (d) overall microstructure showing layer band, welding defect (void) from the top of the sample, and (e)-(g) micrographs using a strong etchant.
Fig. 4. EDS mapping of the bright dendritic network of H13 (a) original microstructure. White arrows denote unidentified objects, (b) EDS map of Molybdenum, and (c) EDS map of Chromium. Yellow arrows denote high Mo and Cr content of the bright dendritic network.
Fig. 5. SEM micrographs at different locations of the microstructure showing (a) irregular-shaped grain boundary pore (GP), and grain boundary carbide (GC); (b) martensite (M), retained austenite (RA) and martensitic packet (MP); (c) higher magnified view of the red boundary area of Fig. 5(a); (d) grain boundary showing over the RA pore (OP) and over the RA carbide (OC).
Fig. 6. EDS mapping showing carbide composition (top). (a) Light-etched microstructure. Red arrow - higher amount of Silicon (Si), brown arrow-higher amount of Vanadium (V), and violet arrow - higher amount of Molybdenum (Mo). PM - phase map; OM - element overlay map; V, Mo, Si are corresponding element map.
Elements | Spots | Typical wire composition (%wt.) | ||
---|---|---|---|---|
Spot 1 (bright carbide) (%wt.) | Spot 2 (grey carbide) (%wt.) | Spot 3 (martensitic phase) (%wt.) | ||
Fe | 57.80 | 51.14 | 91.38 | 90.55 |
Cr | 12.77 | 7.46 | 4.88 | 5.0 |
Mo | 18.25 | 6.35 | 0.29 | 1.5 |
V | 3.57 | 24.83 | 0.84 | 1.0 |
C | 6.28 | 8.98 | 1.83 | 0.35 |
Table 2 Compositional analysis on different spots of the microstructure in Fig. 6.
Elements | Spots | Typical wire composition (%wt.) | ||
---|---|---|---|---|
Spot 1 (bright carbide) (%wt.) | Spot 2 (grey carbide) (%wt.) | Spot 3 (martensitic phase) (%wt.) | ||
Fe | 57.80 | 51.14 | 91.38 | 90.55 |
Cr | 12.77 | 7.46 | 4.88 | 5.0 |
Mo | 18.25 | 6.35 | 0.29 | 1.5 |
V | 3.57 | 24.83 | 0.84 | 1.0 |
C | 6.28 | 8.98 | 1.83 | 0.35 |
Fig. 7. Area mapping of the austenitic grain boundary. (a) EDS image showing austenitic grain boundary. The orange square area is EDS mapped. (b) EDS map of Cr, (c) EDS map of Mo.
Fig. 8. FESEM image at the austenitic grain boundary: (a) yellow arrows denote Mo-rich carbides, (b) yellow arrows denote V-rich carbides. For both images, red arrows denote dispersed Cr particles.
Fig. 11. (a) Area of the voids along the z-direction at the top parts evaluated by DIA. (b)-(c) Microstructure at the darkened topmost part of Fig. 3(d) where the yellow arrows denote, (b) grain boundary pore dispersed through the microstructure, (c) grain boundary crack.
Fig. 13. Tensile result. (a) Average ultimate tensile strength, yield strength, and elongation; and (b) comparative plot of the stress-strain curve at different conditions.
Processing Technology | Yield strength (MPa) | Ultimate tensile strength (MPa) | Elongation (%) | |
---|---|---|---|---|
ASM Standard* [ | Room temperature | 1290 | 1490 | 15.4 |
425ºC | 1005 | 1200 | 17.0 | |
595ºC | 690 | 827 | 22.6 | |
CMT-WAAM | 23 °C | 1145.14 | 1303.83 | 8.60 |
300ºC | 1013.6 | 1139.69 | 7.78 | |
600 °C | 803.95 | 815.03 | 8.58 | |
GMAW-WAAM (Vertical to Build Direction) [ | 750 (Approximate from the graph) | 871 | 8.2 | |
CMT-WAAM [ | - | 1322 | 10.53 | |
As-SLMed [ | 1236 ± 178 | 1712 ± 103 | 4.1 ± 1.2 | |
As-SLMed [ | - | 1600 ± 50 | ~1.5 | |
As-SLMed at 600 °C (along build direction) [ | 1084 ± 33 | 1203 ± 6 | 7.7 ± 0.70 |
Table 3 Mechanical properties of AISI type H13 tool steel: Comparison of CMT-WAAM with other AM methods.
Processing Technology | Yield strength (MPa) | Ultimate tensile strength (MPa) | Elongation (%) | |
---|---|---|---|---|
ASM Standard* [ | Room temperature | 1290 | 1490 | 15.4 |
425ºC | 1005 | 1200 | 17.0 | |
595ºC | 690 | 827 | 22.6 | |
CMT-WAAM | 23 °C | 1145.14 | 1303.83 | 8.60 |
300ºC | 1013.6 | 1139.69 | 7.78 | |
600 °C | 803.95 | 815.03 | 8.58 | |
GMAW-WAAM (Vertical to Build Direction) [ | 750 (Approximate from the graph) | 871 | 8.2 | |
CMT-WAAM [ | - | 1322 | 10.53 | |
As-SLMed [ | 1236 ± 178 | 1712 ± 103 | 4.1 ± 1.2 | |
As-SLMed [ | - | 1600 ± 50 | ~1.5 | |
As-SLMed at 600 °C (along build direction) [ | 1084 ± 33 | 1203 ± 6 | 7.7 ± 0.70 |
Fig. 14. Fractured surface images of the tensile specimens tested at room temperature. (a) Overall fractured surface. Area enclosed by (i) the green-yellow boundary-shear lip, (ii) yellow-pink region-radial shear, (iii) pink boundary-fibrous; (b) higher magnification view of the blue square enclosed part of Fig. 12(a); (c) higher magnification view of the brown-colored square enclosed part of Fig. 12(a).
Fig. 15. Fractured surface micrographs of tensile-tested specimens at 300 °C. (a) Overall fractured surface. Pink arrows denote brittle fracture zone as well as RS + F zone, (b) higher magnification view showing cleavage steps (pink arrows), (c) fracture characteristics near defects.
Fig. 16. Fractured surface images tensile tested at 600 °C. (a) Overall fractured zone, (b) higher magnification view at RS + F region. Pink arrows denote cleavage step, (c) dimpled surface with an elongated pore (pink arrows).
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