A new technology for producing defect-free metal 3D products has been developed in Perm.

3D printing is gaining increasing traction in the fields of medicine, automotive, and aerospace due to its ability to produce complex, defect-free components with excellent mechanical properties. The technology of wire-arc additive manufacturing is being utilized more frequently for the production of large-scale parts. For instance, in aerospace engine manufacturing, many components for compressors and nozzle sections can be produced. However, during the printing process, certain effects can alter the structure and properties of the finished products, compromising their quality and lifespan. Researchers at Perm Polytechnic University have developed a new method—laser wire deposition with controlled metal transfer. They have created a prototype of the equipment and optimized the necessary parameters for depositing nickel-chromium heat-resistant alloys. This advancement will enable the production of reliable components with minimal need for additional processing.

2024-11-12 10:00:24https://naked-science.ru/article/column/metallicheskih-3d-izdelij

The article was published in the journal "Bulletin of PNIPU. Machine Engineering, Materials Science." The research was conducted as part of the strategic academic leadership program "Priority 2030."

Wire-arc additive manufacturing is a technological process where a vertically acting laser source feeds one or more wires from the side, melting them and "growing" a metallic product layer by layer. This technology is rapidly advancing worldwide due to its nearly waste-free material usage and production speed. However, it is crucial to select the correct deposition parameters on a 3D printer for different alloys; otherwise, the material loses its mechanical properties, becomes less durable, and improperly forms layers, leading to deviations in the dimensions and shape of the final parts. There is also a significant risk of micro-porosity on the surface, which can result in the formation and propagation of cracks.

Scientists at Perm Polytechnic University have developed a new method and studied how the power of the laser beam and the speed of the 3D printer's print head affect the quality and shape of the resulting metallic layer. Based on the results, experts determined preliminary deposition parameters for nickel-chromium heat-resistant alloys (e.g., Inconel 718). These alloys are known for their high corrosion resistance and are considered difficult to process due to their complex chemical composition. They are used in equipment operating at high temperatures or in chemically aggressive environments.

“We have developed a unique method of laser wire deposition that allows for the printing of workpieces with minimal allowance for subsequent machining. The new additive manufacturing technology uses a combined laser heat source with controlled distribution in the deposition area and the transfer of melted metal into the product. With this equipment, we performed the deposition of nine individual samples made from the nickel alloy Inconel 718 and examined the influence of various factors on their width and height.

As the movement speed increases and the laser power decreases, the stability of the process deteriorates, leading to the formation of defects. We also identified the optimal parameters for the preliminary deposition mode for additive laser-wire growth of nickel alloy workpieces. This will help improve the strength characteristics of the components,” comments Dmitry Trushnikov, Professor of the "Welding Production, Metrology, and Materials Technology" department at PNIPU, Doctor of Technical Sciences.

The laser wire deposition method in 3D printing, developed by scientists at Perm Polytechnic University, will enable the creation of high-quality metallic products for the engine manufacturing industry, preserving the mechanical properties of the material, as well as the specified dimensions and geometry of the parts.