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- ItemMachine learning for additive manufacturing: Predicting materials characteristics and their uncertainty(Amsterdam [u.a.] : Elsevier Science, 2023) Chernyavsky, Dmitry; Kononenko, Denys Y.; Han, Jun Hee; Kim, Hwi Jun; van den Brink, Jeroen; Kosiba, KonradAdditive manufacturing (AM) is known for versatile fabrication of complex parts, while also allowing the synthesis of materials with desired microstructures and resulting properties. These benefits come at a cost: process control to manufacture parts within given specifications is very challenging due to the relevance of a large number of processing parameters. Efficient predictive machine learning (ML) models trained on small datasets, can minimize this cost. They also allow to assess the quality of the dataset inclusive of uncertainty. This is important in order for additively manufactured parts to meet property specifications not only on average, but also within a given variance or uncertainty. Here, we demonstrate this strategy by developing a heteroscedastic Gaussian process (HGP) model, from a dataset based on laser powder bed fusion of a glass-forming alloy at varying processing parameters. Using amorphicity as the microstructural descriptor, we train the model on our Zr52.5Cu17.9Ni14.6Al10Ti5 (at.%) alloy dataset. The HGP model not only accurately predicts the mean value of amorphicity, but also provides the respective uncertainty. The quantification of the aleatoric and epistemic uncertainty contributions allows to assess intrinsic inaccuracies of the dataset, as well as identify underlying physical phenomena. This HGP model approach enables to systematically improve ML-driven AM processes.
- ItemTemperature-dependent dynamic compressive properties and failure mechanisms of the additively manufactured CoCrFeMnNi high entropy alloy(Oxford : Elsevier Science, 2022) Chen, Hongyu; Liu, Yang; Wang, Yonggang; Li, Zhiguo; Wang, Di; Kosiba, KonradCoCrFeMnNi high entropy alloy (HEA) parts were fabricated by laser powder bed fusion (LPBF), and their dynamic compressive properties at different temperatures as well as the resulting microstructures were analyzed. The HEAs showed an unprecedented strength-ductility combination, especially at a cryogenic temperature of 77 K and a high strain rate of 3000 s−1. Under this testing condition, the yield strength (YS) of the HEAs amounted to 665 MPa. Regardless of the testing temperature, the deformation mechanism of all investigated HEAs was dominated by a synergistic effect consisting of deformation twinning and dislocation pile-up around twins. The fraction of twin boundaries and dislocation density within the deformed microstructure of the HEA correlated with the test temperature. At 77 K, the formation of nanotwins together with dislocation slip prevailed and contributed to pronounced twin-twin and twin-dislocation interactions which effectively restricted the dislocation movement and, hence, contributed to a higher YS as well as strain hardening rate in comparison to that of the HEAs at room temperature of 298 K. The LPBF-fabricated HEAs showed unpronounced thermal softening even at a high testing temperature of 1073 K. Continuous dynamic recrystallization was restricted in the HEA because of its inherent sluggish dislocation kinetics and low stacking fault energy.
- ItemLaser powder bed fusion of Fe60(CoCrNiMn)40 medium-entropy alloy with excellent strength-ductility balance(Amsterdam [u.a.] : Elsevier Science, 2024) Yang, Shengze; Liu, Yang; Chen, Hongyu; Wang, Yonggang; Kosiba, KonradIn this study, Fe60(CoCrNiMn)40 medium-entropy alloy (MEA) was fabricated by laser powder bed fusion (LPBF) via mixing of pure Fe and FeCoCrNiMn powders, the processability, microstructure and mechanical properties were systematically investigated, and the mechanism of strengthening and toughening were revealed through combination of experiments and molecular dynamics (MD) simulations. Results show that fraction of BCC phase decreased gradually with increasing volume energy density (VED), and thus heterostructue with varying FCC and BCC phases were produced through regulating the VED. The Fe60(CoCrNiMn)40 MEA (with scanning speeds of 700 and 800 mm/s) showed excellent strength-plasticity balance (e.g. 476 MPa, 612 MPa and 63 %) compared to the equiatomic FeCoCrNiMn HEA, which is ascribed to the synergistic strengthening and toughening effects involving the twinning induced plasticity (TWIP) and the reinforcement caused by the BCC phase (act as reinforced particle) embedded in the FCC matrix.
- ItemViscous Flow of Supercooled Liquid in a Zr-Based Bulk Metallic Glass Synthesized by Additive Manufacturing(Basel : MDPI, 2020) Kosiba, Konrad; Deng, Liang; Scudino, SergioThe constraint in sample size imposed by the critical cooling rate necessary for glass formation using conventional casting techniques is possibly the most critical limitation for the extensive use of bulk metallic glasses (BMGs) in structural applications. This drawback has been recently overcome by processing glass-forming systems via additive manufacturing, finally enabling the synthesis of BMGs with no size limitation. Although processing by additive manufacturing allows fabricating BMG objects with virtually no shape limitation, thermoplastic forming of additively manufactured BMGs may be necessary for materials optimization. Thermoplastic forming of BMGs is carried out above the glass transition temperature, where these materials behave as highly viscous liquids; the analysis of the viscosity is thus of primary importance. In this work, the temperature dependence of viscosity of the Zr52.5Cu17.9Ni14.6Al10Ti5 metallic glass fabricated by casting and laser powder bed fusion (LPBF) is investigated. We observed minor differences in the viscous flow of the specimens fabricated by the different techniques that can be ascribed to the higher porosity of the LPBF metallic glass. Nevertheless, the present results reveal a similar overall variation of viscosity in the cast and LPBF materials, which offers the opportunity to shape additively manufactured BMGs using already developed thermoplastic forming techniques.
- ItemApproach to Estimate the Phase Formation and the Mechanical Properties of Alloys Processed by Laser Powder Bed Fusion via Casting(Basel : MDPI, 2022) Kühn, Uta; Sander, Jan; Gabrysiak, Katharina Nicole; Giebeler, Lars; Kosiba, Konrad; Pilz, Stefan; Neufeld, Kai; Boehm, Anne Veronika; Hufenbach, Julia KristinA high-performance tool steel with the nominal composition Fe85Cr4Mo8V2C1 (wt%) was processed by three different manufacturing techniques with rising cooling rates: conventional gravity casting, centrifugal casting and an additive manufacturing process, using laser powder bed fusion (LPBF). The resulting material of all processing routes reveals a microstructure, which is composed of martensite, austenite and carbides. However, comparing the size, the morphology and the weight fraction of the present phases, a significant difference of the gravity cast samples is evident, whereas the centrifugal cast material and the LPBF samples show certain commonalities leading finally to similar mechanical properties. This provides the opportunity to roughly estimate the mechanical properties of the material fabricated by LPBF. The major benefit arises from the required small material quantity and the low resources for the preparation of samples by centrifugal casting in comparison to the additive manufacturing process. Concluding, the present findings demonstrate the high attractiveness of centrifugal casting for the effective material screening and hence development of novel alloys adapted to LPBF-processing.
- ItemPhase Formation, Microstructure and Mechanical Properties of Mg67Ag33 as Potential Biomaterial(Basel : MDPI, 2021) Kosiba, Konrad; Prashanth, Konda Gokuldoss; Scudino, SergioThe phase and microstructure formation as well as mechanical properties of the rapidly solidified Mg67Ag33 (at. %) alloy were investigated. Owing to kinetic constraints effective during rapid cooling, the formation of equilibrium phases is suppressed. Instead, the microstructure is mainly composed of oversaturated hexagonal closest packed Mg-based dendrites surrounded by a mixture of phases, as probed by X-ray diffraction, electron microscopy and energy dispersive X-ray spectroscopy. A possible non-equilibrium phase diagram is suggested. Mainly because of the fine-grained dendritic and interdendritic microstructure, the material shows appreciable mechanical properties, such as a compressive yield strength and Young’s modulus of 245 ± 5 MPa and 63 ± 2 GPa, respectively. Due to this low Young’s modulus, the Mg67Ag33 alloy has potential for usage as biomaterial and challenges ahead, such as biomechanical compatibility, biodegradability and antibacterial properties are outlined.
- ItemEffect of scanning strategy on microstructure and mechanical properties of a biocompatible Ti–35Nb–7Zr–5Ta alloy processed by laser-powder bed fusion(Berlin : Springer, 2022) Batalha, Weverson Capute; Batalha, Rodolfo Lisboa; Kosiba, Konrad; Kiminami, Claudio Shyinti; Gargarella, PiterThe influence of scanning strategy (SS) on microstructure and mechanical properties of a Ti–35Nb–7Zr–5Ta alloy processed by laser-powder bed fusion (L-PBF) is investigated for the first time. Three SSs are considered: unidirectional-Y; bi-directional with 79° rotation (R79); and chessboard (CHB). The SSs affect the type and distribution of pores. The highest relative densities and more homogeneous distribution of pores are obtained with R79 and CHB scanning strategies, whereas aligned pores are formed in the unidirectional-Y. The SSs show direct influence on the crystallographic texture with unidirectional-Y strategy showing fiber texture. The R79 strategy results in a weak texture and the CHB scanning strategy forms a randomly oriented heterogeneous grain structure. The lowest Young modulus is obtained with the unidirectional-Y strategy, whereas the R79 strategy results in the highest yield strength. It is shown that the SSs may be used for tuning the microstructure of a beta-Ti alloy in L-PBF.
- ItemTowards the better: Intrinsic property amelioration in bulk metallic glasses(London : Nature Publishing Group, 2016) Sarac, Baran; Zhang, Long; Kosiba, Konrad; Pauly, Simon; Stoica, Mihai; Eckert, JürgenTailoring the intrinsic length-scale effects in bulk metallic glasses (BMGs) via post-heat treatment necessitates a systematic analyzing strategy. Although various achievements were made in the past years to structurally enhance the properties of different BMG alloys, the influence of short-term sub-glass transition annealing on the relaxation kinetics is still not fully covered. Here, we aim for unraveling the connection between the physical, (thermo)mechanical and structural changes as a function of selected pre-annealing temperatures and time scales with an in-house developed Cu46Zr44Al8Hf2 based BMG alloy. The controlled formation of nanocrystals below 50 nm with homogenous distribution inside the matrix phase via thermal treatment increase the material’s resistance to strain softening by almost an order of magnitude. The present work determines the design aspects of metallic glasses with enhanced mechanical properties via nanostructural modifications, while postulating a counter-argument to the intrinsic property degradation accounted for long-term annealing.
- ItemLaser additive manufacturing of Miura-origami tube inspired quasi-zero stiffness metamaterial with prominent longitudinal wave propagation(London [u.a.] : Taylor and Francis, 2023) Wan, Haoran; Chen, Hongyu; Wang, Yonggang; Fang, Xiang; Liu, Yang; Kosiba, KonradOrigami metamaterials have become frontiers of research in many disciplines due to their infinite design space, simple size variation, and topologically variable properties. In this study, a novel metamaterial inspired by Miura-origami tubes with a complex quasi-zero-stiffness (QZS) structure was fabricated via laser powder bed fusion (LPBF). The unit of the QZS metamaterial consists of a two-layer quadrilateral frame and two vertical springs attached to its diagonal points. The geometric accuracy, densification level and mechanical properties of the QZS parts fabricated at various processing conditions were investigated and the optimised processing parameters were determined. The displacement response of the QZS parts was analysed by experiments in conjunction with simulation analysis. The results show that the LPBF-fabricated QZS metamaterials form four extra-wide longitudinal wave band gaps under low frequencies from 660 Hz to 2500 Hz. The proposed LPBF-fabricated QZS metamaterial shows great potential in impeding the longitudinal vibration of engineering structures.