The authors report on pulsed laser powder bed fusion fabrication of nitinol (NiTi) shape memory materials. The authors first performed single-track laser parameter sweeps to assess melt pool stability and determine energy parameters and hatch spacing for larger builds. The authors then assessed the melt pool chemistry as a function of laser energy density and build plate composition. Brittle intermetallics were found to form at the part/build plate interface for both N200 and Ti-6-4 substrates. The intermetallic formation was reduced by building on a 50Ni–50Ti substrate, but delamination still occurred due to thermal stresses upon cooling. The authors were able to overcome delamination on all substrates and fabricate macroscopic parts by building a lattice support structure, which is both compliant and controls heat transfer into the build plate. This approach will enable scalable fabrication of complex NiTi parts.
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The authors thank Zachary Ulbig for assistance in running the Additive Manufacturing system utilized for this work. This work was supported by the JHU/APL Research and Exploratory Development Independent Research and Development Program.
The supplementary material for this article can be found at: https://doi.org/10.1557/mrc.2019.134.
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McCue, I., Peitsch, C., Montalbano, T. et al. Scalable laser powder bed fusion processing of nitinol shape memory alloy. MRS Communications 9, 1214–1220 (2019). https://doi.org/10.1557/mrc.2019.134