Performance and repair applications of 18Ni-300 maraging steel printed with micro-spot laser directed energy deposition
department or school: Applied Science, Faculty of
department or school: Engineering, School of (Okanagan)
data provider: DSpace
degree campus: UBCO
creator: Paul, Christopher G. M.
issued: 2024-09-16T07:00:00Z
issued: 2024
related degree: Master of Applied Science - MASc
degree grantor: University of British Columbia
description: Additive manufacturing (AM) technologies are invaluable for the manufacturing industry by enabling the repair of high-value components. Utilizing AM technology such as laser-directed energy deposition (L-DED) to repair casting inserts can increase tool life, reduce metal waste, and lower operating costs. Typically, L-DED systems employ a 1–3 mm diameter laser spot to melt feedstock material. However, recently developed micro-spot L-DED systems, if optimized correctly, could enhance repair applications by creating smaller beads and minimizing heat input. This thesis aims to define suitable parameters for a micro-spot L-DED system and apply these parameters to a proof-of-concept repair process for a high-pressure die casting (HPDC) insert. By varying main L-DED printing parameters, the deposition behaviour and process parameters for achieving high-density maraging steel were determined using a micro-spot L-DED system. Analyzing the aspect ratio and dilution relationship of beads defined a processing window for the ideal bead shape. Volumetric samples were then printed, and process parameters which created high-density material (>99%) were selected. Compared to larger laser diameters, the 0.3 mm laser significantly influences bead formation characteristics, weld pool stability, part shape accuracy, and internal defects. Internal defects such as pores and titanium oxide inclusions reduce tensile strength and ductility for this material. Variations in grain structures found throughout the deposited material were correlated with changes in cooling rate during L-DED processing. The developed L-DED repair process for the damaged HPDC insert removes the heat checking crack and deposits material with micro-spot L-DED, restoring the component’s geometry. After the repair process, external and internal analyses provide valuable insights into the geometrical accuracy of the repair region, the microstructural and microhardness differences iii between the softer deposited material…
aggregated CHO: https://circle.library.ubc.ca/rest/handle/2429/89000
note: Performance and Repair Applications of 18Ni-300 Maraging Steel Printed with Micro-spot Laser Directed Energy Deposition by Christopher G. M. Paul B.A.Sc., The University of British Columbia, 2022 A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIRMENTS FOR THE DEGREE OF MASTER OF APPLIED SCIENCE in THE COLLEGE OF GRADUATE STUDIES (Mechanical Engineering) THE UNIVERSITY OF BRITISH COLUMBIA (Okanagan) August 2024 © Christopher G. M. Paul, 2024 i The following individuals certify that they have read, and recommend to the College of Graduate Studies for acceptance, a thesis entitled: Performance and Repair Applications of 18Ni-300 Maraging Steel Printed with Micro-spot Laser Directed Energy Deposition submitted by Christopher G. M. Paul in partial fulfillment of the requirements of the degree of Master of Applied Science. Dr. Michael Benoit, University of Waterloo, Mechanical and Mechatronics Engineering Supervisor Dr. Lisa Tobber, School of Engineering Co-Supervisor Dr. Alexander Uhl, School of Engineering Supervisory Committee Member Supervisory Committee Member University Examiner Dr. Ian Foulds, School of Engineering Dr. Christopher Collier, School of Engineering ii Abstract Additive manufacturing (AM) technologies are invaluable for the manufacturing industry by enabling the repair of high-value components. Utilizing AM technology such as laser-directed energy deposition (L-DED) to repair casting inserts can increase tool life, reduce metal waste, and lower operating costs. Typically, L-DED systems employ a 1–3 mm diameter laser spot to melt feedstock material. However, recently developed micro-spot L-DED systems, if optimized correctly, could enhance repair applications by creating smaller beads and minimizing heat input. This thesis aims to define suitable parameters for a micro-spot L-DED system and apply these parameters to a proof-of-concept repair process for a high-pressure die casting (HPDC) insert. By varying main L-DED printing parameters, the deposit…
has type: Thesis/Dissertation
date issued: 2024-11
is shown at: 10.14288/1.0445126
language: eng
degree discipline: Mechanical Engineering
provider: Vancouver : University of British Columbia Library
publisher: University of British Columbia
rights: Attribution-NonCommercial-NoDerivatives 4.0 International
rights URI: http://creativecommons.org/licenses/by-nc-nd/4.0/
scholar level: Graduate
contributor: Benoit, Michael J.
contributor: Tobber, Lisa
type: Text
identifier URI: http://hdl.handle.net/2429/89000