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Friction deposition additive manufacturing of alloy 718: Effect of post-heat treatment on microstructures and mechanical properties

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Abstract

The friction deposition process is well known for surface repairs and depositing corrosion and wear resistant coatings. In this study, we explored friction deposition additive manufacturing (FDAM) for producing alloy 718 components. The microstructure evolution, temperature distribution during the process, and room temperature tensile properties of the FDAM processed alloy 718 were studied. Multi-layer deposits with sound metallurgical bonding at the layer interfaces were obtained. The deposits showed fine equiaxed grains with grain size varying from 4 to 7 μm across the deposit height, having finer grains (~4 μm) closer to the substrate and coarser grains (~7 μm) at the top of the deposit. Thermography analysis was employed to analyze the temperature distribution during friction deposition, revealing a maximum peak temperature of 1121°C on the deposited material. Subsequently, the material cooled rapidly at a rate of 30°C/s. The FDAM sample in the as-deposited condition exhibited higher tensile strength than the wrought alloy 718 in the solution-treated (ST) condition. The post-direct aging (DA) of the FDAM sample resulted in a 41% improvement in tensile strength than the as-deposited condition and met the tensile properties of wrought alloy 718 in aged condition as per aerospace material specifications (AMS). Furthermore, there were no significant variations observed in the tensile properties across different regions of the FDAM deposit height.

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Data availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

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Acknowledgements

The authors would like to thank the joining and additive manufacturing laboratory, Indian Institute of Technology Madras (IITM), India for facilitating the friction deposition  machine to conduct the FDAM experiments.

Funding

This work was supported by the Department of Science and Technology (DST), Science and Engineering Research Board (SERB), Early Career Research (ECR) Award (Ref: ECR/2015/000416).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Sri Sivasubramaniya Nadar College of Engineering, Chennai, 603110, India

    Cyril Joseph Daniel Santiagu, Damodaram Ramachandran & Koteswara Rao Sajja Rama

  2. Department of Mechanical Engineering, Indian Institute of Technology (BHU), Varanasi, Uttar Pradesh, 221005, India

    Manogna Karthik Gangaraju

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  1. Cyril Joseph Daniel Santiagu
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  2. Damodaram Ramachandran
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Contributions

Mr. Cyril Joseph Daniel Santiagu: Conceptualization, Material preparation, Experimental design, Characterization, Data collection and Manuscript writing. Dr. Damodaram Ramachandran: Conceptualization, Funding acquisition, Experimental design, Characterization, Data collection, Manuscript writing, review and editing. Dr. Karthik Gangaraju Manogna: Conceptualization, Characterization, Result analysis, Manuscript review and editing. Dr. Sajja Rama Koteswara Rao: Result analysis, Manuscript review and editing. All authors reviewed and provided comments regarding previous versions of the manuscript and approved the final version of the manuscript.

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Correspondence to Damodaram Ramachandran.

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Santiagu, C.J.D., Ramachandran, D., Gangaraju, M. et al. Friction deposition additive manufacturing of alloy 718: Effect of post-heat treatment on microstructures and mechanical properties. Int J Adv Manuf Technol 128, 3901–3919 (2023). https://doi.org/10.1007/s00170-023-12141-2

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