Multi-material metallic structure fabrication using electron beam melting

  • Cesar A. Terrazas
  • Sara M. Gaytan
  • Emmanuel Rodriguez
  • David Espalin
  • Lawrence E. Murr
  • Francisco Medina
  • Ryan B. Wicker
ORIGINAL ARTICLE
First Online:
Received:
Accepted:

Abstract

The fabrication of multi-material structures using Ti–6Al–4V and copper was explored with the additive manufacturing (AM) technology of electron beam melting (EBM). A new method was developed that included multiple build sequences to accommodate both materials. The process was enabled by machining a start plate so that the parts built with the first material could be press fit into the plate, providing a flat surface on which the second material fabrication would occur. This method provided the ability to fabricate simple multiple metallic material components built in the Z and X directions [1]. Registration of the electron beam was performed manually resulting in slight misalignment for the shift of diameters of specimens built in the Z direction, and along the width and length for specimens built in the X direction. Microstructures observed and hardness values measured for copper and Ti–6Al–4V were different to those observed in normally fabricated EBM parts. These observations might be explained by the different processing conditions required for multi-material fabrication in contrast to the regular EBM process where parts are built in a single machine run. The hardness profiles for as-fabricated and HIPed multi-material parts depicted an increase in hardness for both materials close to the interface with values leveling off to those of single material EBM fabricated parts as measurements proceeded away from the interface. As the benefits of EBM processing are exploited, the method introduced in this research can have profound implications in many technological applications including metal extraction, energy production and for the repair of metallic components.

Keywords

Additive manufacturing Multi-material fabrication Copper Titanium Ti-6Al-4V EBM 
This is a preview of subscription content, log in to check access.

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

References

  1. 1.
    American Society for Testing and Materials, Standard F2921-11 (2012) Standard Terminology for Additive Manufacturing–Coordinate Systems and Test Methodologies. ASTM International, West Conshohocken. doi: 10.1520/F2921-11 Google Scholar
  2. 2.
    American Society for Testing and Materials, Standard F2792-12a (2012) Standard Terminology for Additive Manufacturing Technologies. ASTM International, West Conshohocken. doi: 10.1520/F2792-12A
  3. 3.
    Wicker R, MacDonald E (2012) Multi-material, multi-technology stereolithography. Virtual and Physical Prototyping 7(3):181–194CrossRefGoogle Scholar
  4. 4.
    Choi J, Kim H, Wicker R (2011) Multi-material stereolithography. Journal of Materials Processing Technology 211:318–328CrossRefGoogle Scholar
  5. 5.
    Choi J, MacDonald E, Wicker R (2010) Multi-material microstereolithography. International Journal of Advanced Manufacturing Technology 49:543–551CrossRefGoogle Scholar
  6. 6.
    Arcaute K, Mann B, Wicker R (2010) Stereolithography of spatially controlled multi-material bioactive poly(ethylene glycol) scaffolds. Acta Biomaterialia 6:1047–1054CrossRefGoogle Scholar
  7. 7.
    Lopes A, MacDonald E, Wicker R (2012) Integrating stereolithography and direct print technologies for 3D structural electronics fabrication. Rapid Prototyping Journal 18:129–143CrossRefGoogle Scholar
  8. 8.
    Sigmarsson H, Kinzel E, Chappell W, Xu X (2006) Selective laser sintering of multilayer, multimaterial circuit components. IEEE MTT-S International Microwave Symposium Digest June 2006:1788–1791Google Scholar
  9. 9.
    Chung H, Das S (2008) Functionally graded nylon-11/silica nanocomposites produced by selective laser sintering. Materials Science and Engineering A-487:251–257CrossRefGoogle Scholar
  10. 10.
    Griffith ML, Harwell LD, Romero JT (1997) Multi-material processing by LENS™. Working paper. Sandia National LaboratoriesGoogle Scholar
  11. 11.
    Balla V, Xue W, Bose S, Bandyopadhyay A (2008) Functionally graded Co–Cr–Mo coating on Ti–6Al–4V alloy structures. Acta Biomaterialia 4:697–706Google Scholar
  12. 12.
    Balla V, Bandyopadhyay P, Bose S, Bandyipadhyay A (2007) Compositionally graded yttria-stabilized zirconia coating on stainless steel using laser engineered net shaping (LENSTM). Scripta Materialia 57:861–864Google Scholar
  13. 13.
    Obielodan J, Stucker B (2010) Dual-material minimum weight structures fabrication using ultrasonic consolidation. In 21st Annual International Solid Freeform Fabrication Symposium, August 2010: 48–81Google Scholar
  14. 14.
    Sun Z, Karppi R (1996) The application of electron beam welding for the joining of dissimilar metals: an overview. Journal of Materials Processing Technology 39:257–267CrossRefGoogle Scholar
  15. 15.
    Obielodan J, Ceylan A, Murr L, Stucker B (2010) Multi-material bonding in ultrasonic consolidation. Rapid Prototyping Journal 16:180–188CrossRefGoogle Scholar
  16. 16.
    Murr L, Esquivel E, Quinones S, Gaytan S, Lopez M, Martinez E, Medina F, Hernandez D, Martinez E, Martinez J, Stafford S, Brown D, Hoppe T, Meyers W, Lindhe U, Wicker R (2009) Microstructures and mechanical properties of electron beam-rapid manufactured Ti–6Al–4V biomedical prototypes compared to wrought Ti–6Al–4V. Materials characterization 60:96–105CrossRefGoogle Scholar
  17. 17.
    Ramirez D, Murr L, Martinez E, Hernandez D, Martinez J, Machado B, Medina F, Frigola P, Wicker R (2011) Novel precipitate-microstructural architecture developed in the fabrication of solid copper components by additive manufacturing using electron beam melting. Acta Materialia 59:4088–4099CrossRefGoogle Scholar
  18. 18.
    Thijs L, Verhaeghe F, Craeghs T, Humbeeck J, Kruth J (2010) A study of the microstructural evolution during selective laser melting of Ti–6Al–4V. Acta Materialia 58:3303–3312CrossRefGoogle Scholar
  19. 19.
    MatWeb (2013) Material Property Data. Ti-6Al-4V (Grade 5), Annealed Bar. http://www.matweb.com/search/DataSheet.aspx?MatGUID=10d463eb3d3d4ff48fc57e0ad1037434. Accessed 20 January 2013
  20. 20.
    MatWeb (2013) Material Property Data. Copper, Cu: Annealed. http://matweb.com/search/DataSheet.aspx?MatGUID=9aebe83845c04c1db5126fada6f76f7e. Accessed 20 January 2013
  21. 21.
    Rosa J, Robin A, Silva M, Baldan C, Peres M (2009) Electrodeposition of copper on titanium wires: Taguchi experimental design approach. Journal of Materials Processing Technology 209:1181–1188CrossRefGoogle Scholar
  22. 22.
    Demidenko L, Onatskaya N (2008) Solid-state welding of tubular joints of titanium and copper with application of electrohydropulse loading. Surface Engineering and Applied Electrochemistry 44:245–247CrossRefGoogle Scholar
  23. 23.
    Kline G, (1983) Titanium clad copper electrode and method for making. U.S. Patent No. 4,411,762Google Scholar
  24. 24.
    Oberg E, Jones F, Horton H, Ryffel H (1996) Machinery's handbook, 25th Edition. New York, USAGoogle Scholar
  25. 25.
    Engineers Edge (2013) Dowel Pin Tolerance Chart – ASME Y14.5-2009. http://www.engineersedge.com/dowel_pin.htm. Accessed 6 March 2013
  26. 26.
    Froes F, Mashl S, Moxson V, Hebeisen J, Duz V (2004) The technologies of titanium powder metallurgy. JOM: 46–48Google Scholar
  27. 27.
    Teodorescu G (2007) Radiative emissivity of metals and oxidized metals at high temperature. Dissertation, Auburn UniversityGoogle Scholar
  28. 28.
    Arcam A2 System Technical Data (2013) http://www.arcam.com/CommonResources/Files/www.arcam.com/Documents/Products/Arcam-A2.pdf. Accessed 3 March 2013
  29. 29.
    Versnyder F, Shank M (1970) The development of columnar grain and single crystal high temperature materials through directional solidification. Materials Science and Engineering 6:213–247CrossRefGoogle Scholar
  30. 30.
    Field D, Bradford L, Nowell M, Lillo T (2007) The role of annealing twins during recrystallization of Cu. Acta Materialia 55:4233–4241CrossRefGoogle Scholar
  31. 31.
    Koike M, Martinez K, Guo L, Chahine G, Kovacevic R, Okabe T (2011) Evaluation of titanium alloy fabricated using electron beam melting system for dental applications. Journal of Materials Processing Technology 211:1400–1408CrossRefGoogle Scholar
  32. 32.
    Karlsson J, Snis A, Engqvist H, Lausmaa J (2013) Characterization and comparison of materials produced by Electron Beam Melting (EBM) of two different Ti–6Al–4V powder fractions. Journal of Materials Processing Technology 213:2109–2118CrossRefGoogle Scholar
  33. 33.
    Bolzoni L, Montealegre I, Ruiz-Navas E, Gordo E (2012) Microstructural evolution and mechanical properties of the Ti–6Al–4V alloy produced by vacuum hot-pressing. Materials Science and Engineering A-546:189–197Google Scholar
  34. 34.
    Nesterenko V, Goldsmith W, Indrakanti S, Gu Y (2003) Response of hot isostatically pressed Ti–6Al–4V targets to normal impact by conical and blunt projectiles. International Journal of Impact Engineering 28:137–160Google Scholar
  35. 35.
    Srivatsan T, Ravi B, Naruka A, Petraroli M, Kalyanamaran R, Sudarshan T (2002) Influence of consolidation parameters on the microstructure and hardness of bulk copper samples made from nanopowders. Materials and Design 23:291–296CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London 2013

Authors and Affiliations

  • Cesar A. Terrazas
    • 1
  • Sara M. Gaytan
    • 1
  • Emmanuel Rodriguez
    • 1
  • David Espalin
    • 1
  • Lawrence E. Murr
    • 2
  • Francisco Medina
    • 1
  • Ryan B. Wicker
    • 1
  1. 1.W. M. Keck Center for 3D InnovationUniversity of Texas at El PasoEl PasoUSA
  2. 2.Metallurgical and Materials Engineering DepartmentUniversity of Texas at El PasoEl PasoUSA

Personalised recommendations