PSI - Issue 54

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ScienceDirect

Procedia Structural Integrity 54 (2024) 626–630 Structural Integrity Procedia 00 (2023) 000–000 Structural Integrity Procedia 00 (2023) 000–000

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© 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0 ) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers. Keywords: Additive Manufacturing; Design of Experiments; Direct Energy Deposition Abstract Laser Metal Deposition (LMD) ability to precisely fabricate complex geometries layer by layer, along with its capability to repair and enhance existing components, has ushered in new frontiers of design freedom and innovation. As industries continually seek solutions for increased e ffi ciency and performance, LMD o ff ers an avenue to unlock novel possibilities, enabling the production of high-quality, intricately designed parts while simultaneously reducing material waste, with significant build rate when compared to other metal AM processes. The unique properties of nickel-based superalloys, including exceptional high-temperature strength and corrosion resistance, make them indispensable materials for critical applications, particularly in aerospace, power generation, and the energy sector. This research paper presents a comprehensive investigation into the process optimization of laser melting deposition for Inconel 625, a high-performance nickel-chromium-based superalloy. The study employed a center cubic design as a Design of Experiments (DoE) framework, with a primary focus on achieving the maximum tensile strength as the optimization objective. A series of quasi-static tensile tests was conducted to evaluate the mechanical properties of the deposited material, while optical microscopy was utilized to analyze the cross-sectional characteristics, including deposition density and defect sizes. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers. Keywords: Additive Manufacturing; Design of Experiments; Direct Energy Deposition International Conference on Structural Integrity 2023 (ICSI 2023) Design of Experiments based optimization of Direct Energy Deposition Inconel 625 processing for a power generation turbine blade Daniel F.O. Braga a, ∗ , Lucas Azevedo b , G. Cipriano a , Pedro M.G.P. Moreira a a INEGI, Campus da FEUP, Universidade Do Porto, Rua Dr. Roberto Frias, 400, 4200-465, Porto, Portugal b Quantal S. A., Rua Sa˜o Cristo´va˜o, 95, 4480-430, Rio Mau, Vila do Conde, Portugal Abstract Laser Metal Deposition (LMD) ability to precisely fabricate complex geometries layer by layer, along with its capability to repair and enhance existing components, has ushered in new frontiers of design freedom and innovation. As industries continually seek solutions for increased e ffi ciency and performance, LMD o ff ers an avenue to unlock novel possibilities, enabling the production of high-quality, intricately designed parts while simultaneously reducing material waste, with significant build rate when compared to other metal AM processes. The unique properties of nickel-based superalloys, including exceptional high-temperature strength and corrosion resistance, make them indispensable materials for critical applications, particularly in aerospace, power generation, and the energy sector. This research paper presents a comprehensive investigation into the process optimization of laser melting deposition for Inconel 625, a high-performance nickel-chromium-based superalloy. The study employed a center cubic design as a Design of Experiments (DoE) framework, with a primary focus on achieving the maximum tensile strength as the optimization objective. A series of quasi-static tensile tests was conducted to evaluate the mechanical properties of the deposited material, while optical microscopy was utilized to analyze the cross-sectional characteristics, including deposition density and defect sizes. International Conference on Structural Integrity 2023 (ICSI 2023) Design of Experiments based optimization of Direct Energy Deposition Inconel 625 processing for a power generation turbine blade Daniel F.O. Braga a, ∗ , Lucas Azevedo b , G. Cipriano a , Pedro M.G.P. Moreira a a INEGI, Campus da FEUP, Universidade Do Porto, Rua Dr. Roberto Frias, 400, 4200-465, Porto, Portugal b Quantal S. A., Rua Sa˜o Cristo´va˜o, 95, 4480-430, Rio Mau, Vila do Conde, Portugal

1. Introduction 1. Introduction

Nickel-based superalloys high temperature strength and corrosion resistance, makes them prime materials for high temperature, high demanding applications, such as gas turbine blades. However their mechanical properties makes them challenging materials to manufacture with in subtractive processes. LMD with its high deposition rate is a valid alternative to manufacture with these materials. Also by employing metal additive manufacturing, further optimization Nickel-based superalloys high temperature strength and corrosion resistance, makes them prime materials for high temperature, high demanding applications, such as gas turbine blades. However their mechanical properties makes them challenging materials to manufacture with in subtractive processes. LMD with its high deposition rate is a valid alternative to manufacture with these materials. Also by employing metal additive manufacturing, further optimization

∗ Corresponding author. Tel.: + 351 229578710 ; fax: + 351 229537352. E-mail address: dbraga@inegi.up.pt ∗ Corresponding author. Tel.: + 351 229578710 ; fax: + 351 229537352. E-mail address: dbraga@inegi.up.pt

2452-3216 © 2023 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers 10.1016/j.prostr.2024.01.127 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers. 2210-7843 © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the ICSI 2023 organizers.