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Scalable laser powder bed fusion processing of nitinol shape memory alloy

Published online by Cambridge University Press:  26 September 2019

Ian McCue ,
Christopher Peitsch ,
Tim Montalbano ,
Andrew Lennon ,
Joseph Sopcisak ,
Morgana M. Trexler  and
Steven Storck
Ian McCue
Affiliation:
Research and Exploratory Development Department, The Johns Hopkins University Applied Physics Laboratory (JHU/APL), Laurel, MD20723, USA
Christopher Peitsch
Affiliation:
Research and Exploratory Development Department, The Johns Hopkins University Applied Physics Laboratory (JHU/APL), Laurel, MD20723, USA
Tim Montalbano
Affiliation:
Research and Exploratory Development Department, The Johns Hopkins University Applied Physics Laboratory (JHU/APL), Laurel, MD20723, USA
Andrew Lennon
Affiliation:
Research and Exploratory Development Department, The Johns Hopkins University Applied Physics Laboratory (JHU/APL), Laurel, MD20723, USA
Joseph Sopcisak
Affiliation:
Research and Exploratory Development Department, The Johns Hopkins University Applied Physics Laboratory (JHU/APL), Laurel, MD20723, USA
Morgana M. Trexler*
Affiliation:
Research and Exploratory Development Department, The Johns Hopkins University Applied Physics Laboratory (JHU/APL), Laurel, MD20723, USA
Steven Storck*
Affiliation:
Research and Exploratory Development Department, The Johns Hopkins University Applied Physics Laboratory (JHU/APL), Laurel, MD20723, USA
*
Address all correspondence to Steven Storck at steven.storck@jhuapl.edu and Morgan M. Trexler at Morgana.trexler@jhuapl.edu
Address all correspondence to Steven Storck at steven.storck@jhuapl.edu and Morgan M. Trexler at Morgana.trexler@jhuapl.edu
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Abstract

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.

Type
Research Letters
Information
MRS Communications , Volume 9 , Issue 4 , December 2019 , pp. 1214 - 1220
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Copyright
Copyright © Materials Research Society 2019

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