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Characteristics of Bi-metallic Interfaces Formed During Direct Energy Deposition Additive Manufacturing Processing

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Abstract

Various additive manufacturing processes are being evaluated to reduce the time and cost for fabrication of low volume, complex, and multifunctional assemblies. This study evaluated two direct energy deposition processes for the fabrication of large bi-metallic structures. The materials evaluated were Inconel 625 and copper alloy C18150, which are used in various high heat flux applications. Inconel was deposited onto the C18150 substrate using blown powder and wire-fed processes. Complete bonding was obtained in both processes and the resulting interfaces were evaluated using microscopy and indentation testing. Differences were observed in the interface region suggesting the kinetic energy of the blown powder process resulted in more residual stress at the interface, promoting recrystallization and enhanced diffusion. This created a broader interface in the blown powder specimens compared to a narrower mechanically mixed interface with the wire-fed process.

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Acknowledgments

This work was supported in part from NASA STTR Phase I with Keystone Synergistic Enterprises, Inc. Grant No. NNX16CM41P, “Advancing Metal Direct Digital Manufacturing (MDDM) Processes for Reduced Cost Fabrication of Bi-Metallic Cooled Rocket Engines,” and Aetos Systems Grant No. NNM14AA15C/Subcontract No. 2019. A52, “Additive/subtractive manufacturing of combustion devices.”

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Authors and Affiliations

  1. Department of Mechanical and Aerospace Engineering, University of Alabama in Huntsville, Huntsville, AL, 35899, USA

    Ryan Anderson, Jordan Terrell & Judy Schneider

  2. US Army CCDC Aviation and Missile Center, Redstone Arsenal, AL, 35898, USA

    Sean Thompson

  3. NASA Marshall Space Flight Center, Huntsville, AL, 35812, USA

    Paul Gradl

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  1. Ryan Anderson
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  2. Jordan Terrell
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Correspondence to Judy Schneider.

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Manuscript submitted December 14, 2018.

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Anderson, R., Terrell, J., Schneider, J. et al. Characteristics of Bi-metallic Interfaces Formed During Direct Energy Deposition Additive Manufacturing Processing. Metall Mater Trans B 50, 1921–1930 (2019). https://doi.org/10.1007/s11663-019-01612-1

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