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Completed TRL 3 (started at 2, targeting 4)
Project Objective
A comprehensive characterization of AM GRCop-42 deposited using infra-red (IR) laser and green laser sources are vital to quantify the potential differences in part quality including microstructure, mechanical, and fatigue properties. This is essential to ensure the safe and successful implementation of AM GRCop-42 processed with different lasers.
Project Description
The project is centered on explaining the interrelationship among microstructural characteristics, mechanical properties at both micro- and macro- (global) scales, and the fatigue performance under force control conditions (R=0.1, 103 to 5×106 cycles) of thin-wall LP-DED GRCop-42 specimens fabricated by green laser and infra-red laser. The hypothesis behind the proposed investigation would then be that the lower heat input required to fully melt the powder during green laser deposition will result in different mechanical properties than the traditional infra-red laser due to different solidification behavior. Therefore, the properties cannot be assumed to be the same for both fabrication processes. Such factors significantly impact key microscopic features, including grain structure (e.g., size, orientation) and volumetric defect characteristics, thereby exerting critical effects on mechanical properties, particularly local properties, and fatigue performance. Therefore, material properties, such as strength and elongation, cannot be assumed to be equal between the two deposition methods.
By undertaking this study, we will not only address a critical gap in the understanding of how different laser sources (green versus infra-red) affect the properties of AM GRCop-42 but also provide invaluable insights that can drive the development of more efficient and cost-effective manufacturing processes as well as characterization methods. This research holds the potential to significantly advance the field of high-performance materials for aerospace applications, aligning with strategic priorities in both academic and industrial settings. Furthermore, the findings from this project could inform the development of new standards and guidelines for the AM industry, ensuring the production of superior quality components for future aerospace innovations.
Project Results and Conclusions
We completed the investigation of the mechanical and microstructural properties of additively manufactured GRCop-42 and GRCop-84 alloys, focusing on correlating nanoindentation metrics with tensile properties to determine the hardness-strength relationship. We found out that L-PBF GRCop-42 samples, characterized by finer and more homogeneous grain structure along with moderate crystallographic texture, exhibit enhanced mechanical performance compared to their LP-DED counterparts. The next step of the project is high cycle fatigue (HCF) tests with R value of 0.1 that is ongoing.
From a manufacturing standpoint, the relationships between the AM heat input sources, the characteristic features of grain structure, and their impacts on local and global mechanical properties, as well as the fatigue performance are quantified. This knowledge will facilitate the optimization of build parameters to enhance part quality, ensuring reliable and efficient implementation of AM GRCop-42 in rocket engine combustion chambers. In particular, the detailed fatigue analysis will provide critical insights into the material's long-term performance under cyclic loading conditions, contributing to safer and more durable LP-DED aerospace components.
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