Wire-based directed energy deposition (DED-wire) used as additive manufacturing technology for industrial Inconel 718 tools for robotic friction stir welding (R-FSW)

The Inconel 718 nickel-base superalloy (IN718) is a high-strength and highly corrosion-resistant material used in several industrial applications. Its high mechanical and chemical properties make this material a focus of interest for additive manufacturing because IN718 is expensive, and a heat trea...

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Bibliographic Details
Published inInternational journal of advanced manufacturing technology Vol. 134; no. 7-8; pp. 3171 - 3180
Main Authors Alvarez-Leal, Marta, Pastor-Cintas, Manuel, Fraile-Martin, Ana, Ureña, Julia
Format Journal Article
LanguageEnglish
Published London Springer London 01.10.2024
Springer Nature B.V
Subjects
Additive manufacturing
CAE) and Design
Chemical properties
Computer-Aided Engineering (CAD
Corrosion products
Corrosion resistance
Design parameters
Engineering
Friction stir welding
Heat treating
Heat treatment
Industrial and Production Engineering
Industrial applications
Industrial robots
Machining
Manufacturing
Mechanical Engineering
Media Management
Nickel base alloys
Original Article
Plant layout
Superalloys
Welding parameters
Wire
Robotic Friction Stir Welding (R-FSW)
Industry
IN718
Additive manufacturing (AM)
Microstructure
Laser Directed Energy Deposition (Laser-DED) processing
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Summary:The Inconel 718 nickel-base superalloy (IN718) is a high-strength and highly corrosion-resistant material used in several industrial applications. Its high mechanical and chemical properties make this material a focus of interest for additive manufacturing because IN718 is expensive, and a heat treatment post-manufacturing is typically needed. This greatly increases costs and production time, with a loss of material due to machining of the material blocks that can be avoided with additive manufacturing by providing material only where needed. For the Robotic Friction Stir Welding (R-FSW), a tool with high performance is demanded. In this work, IN718 tools for the R-FSW process have been additively manufactured with optimized parameters under high manufacturing speed conditions and with the advantages of using metal wire. As-built and heat-treated conditions heat have been microstructural and mechanically analyzed. Finally, different tool designs of the same IN718 DED-wire manufactured material have been tested in several friction stir welds, analyzing their behavior and the relation with the successful welds. Optimal thermal conditions and design parameters for IN718 FSW tools were established.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-024-14314-z