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Laser-Based Directed Energy Deposition of Functionally Graded Metal–Ceramic (NiCr–YSZ) System

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Abstract

Additive manufacturing is emerging as a promising technology for fabrication of compositionally graded materials, especially ceramic coatings over metals. The compositionally graded materials are potential candidates for minimizing residual stresses due to abrupt changes in the thermo-physical properties at the metal–ceramic joints. The performance of these additively manufactured compositionally graded materials depends on the microstructure of each layer and the residual stress distribution. This work presents the results of a study on one such additively deposited metal–ceramic combination, NiCr–YSZ, which finds wide applications in thermal barrier coatings. The composites of NiCr–YSZ with varying YSZ contents viz. 15%, 35% and 65% in NiCr were additively deposited on Ni-base superalloy substrate. The deposits were studied for microstructural characteristics and phase analysis. Thermo-physical properties, such as coefficient of thermal expansion and thermal diffusivity, were also evaluated for NiCr–YSZ composites. Further, NiCr–YSZ material combination was additively deposited as discrete interface and as compositionally graded deposits. The through-thickness residual stresses across the build direction were experimentally determined using micro-focus XRD technique and compared.

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Acknowledgements

The authors gratefully acknowledge the financial support provided by DRDO (project DMR295). Encouragement and support provided by Directory, DMRL to carry out this research work is acknowledged. The authors are grateful to by Dr. Indradev Samajdar, Professor, IIT Bombay and his team for their support in the evaluation of residual stresses. The authors acknowledge the support provided by Light alloy casting group, Failure analysis and Electron microscopy groups of DMRL during different stages of this work.

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Authors and Affiliations

  1. Mishra Dhatu Nigam Limited, Hyderabad, 500058, India

    U. Savitha

  2. Defence Metallurgical Research Laboratory, Hyderabad, 500058, India

    V. Srinivas & G. Jagan Reddy

  3. Indian Institute of Technology, Bombay, Mumbai, 400076, India

    A. A. Gokhale

  4. Indian Institute of Technology, Madras, Chennai, 600036, India

    M. Sundararaman

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  1. U. Savitha
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  2. V. Srinivas
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  3. G. Jagan Reddy
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  4. A. A. Gokhale
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  5. M. Sundararaman
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Correspondence to U. Savitha.

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Savitha, U., Srinivas, V., Reddy, G.J. et al. Laser-Based Directed Energy Deposition of Functionally Graded Metal–Ceramic (NiCr–YSZ) System. Trans Indian Natl. Acad. Eng. 6, 1111–1118 (2021). https://doi.org/10.1007/s41403-021-00282-3

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  • DOI: https://doi.org/10.1007/s41403-021-00282-3

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