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Projeto de investigação
Micro fabrico aditivo por arco elétrico e arame
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Development of a gas metal arc based prototype for direct energy deposition with micrometric wire
Publication . Dornelas, Paulo Henrique Grossi; Oliveira, J. P.; Silva, Tadeu Castro da; Ramos, A. S.; Santos, Telmo G.; DEMI - Departamento de Engenharia Mecânica e Industrial; UNIDEMI - Unidade de Investigação e Desenvolvimento em Engenharia Mecânica e Industrial; DCM - Departamento de Ciência dos Materiais; CENIMAT-i3N - Centro de Investigação de Materiais (Lab. Associado I3N); Elsevier Editora Ltda
In recent years, efforts have been focused on the development of metal additive manufacturing (AM) processes to address the growing trend of miniaturization in industries such as aerospace and electronics. Thus, new technologies have been developed based on a downscaled approach using direct energy deposition (DED) processes, now referred to as μ-DED. In this context, the development of a downscaled DED prototype based on gas metal arc (GMA) working with micrometric wires (μ-GMA) has the potential to unify the positive characteristics of GMA-based DED, increasing the complexity of the design and resolution of the produced parts. Therefore, this work focuses on developing a μ-GMA prototype and assessing its technical feasibility. This paper describes the development of the μ-GMA prototype, characterizes the metallic transfer mode, and statistically analyzes the effect of deposition parameters on bead width and height. Additionally, microstructural analysis, Vickers microhardness, and reduced Young's modulus tests were performed. The μ-GMA prototype demonstrated the capability to deposit beads with an approximate width of 1 mm, nearly 5 times thinner than standard GMA-based DED deposition, with a build rate of 30 cm3/h, which is lower than GMA-based DED but higher than other μ-DED processes. Furthermore, the mechanical properties of the μ-GMA depositions are comparable to regular GMA-based DED parts.
Microstructure, Thermal, and Mechanical Behavior of NiTi Shape Memory Alloy Obtained by Micro Wire and Arc Direct Energy Deposition
Publication . Silva, Tadeu C. da; Sallica-Leva, Edwin; Rayón, Emilio; Santos, Claudio T.; Filho, João C. A. D.; Volpato, Neri; Lima, Dalton D.; Dornelas, Paulo H. G.; Tavares, Sergio S. M.; Santos, Telmo G.; DEMI - Departamento de Engenharia Mecânica e Industrial; UNIDEMI - Unidade de Investigação e Desenvolvimento em Engenharia Mecânica e Industrial; MDPI - Multidisciplinary Digital Publishing Institute
Additive manufacturing (AM) is revolutionizing the fabrication of metallic components, offering significant potential to compete with or complement traditional casting, forging, and machining processes, and enabling the production of complex functional components. Recent advancements in AM technology have facilitated the processing of shape memory alloys (SMAs) with functional properties comparable to those of conventionally processed alloys. However, the AM of NiTi SMAs remains underexplored due to the extreme complexity of the process, high melting point, and reactivity with oxygen. This study investigates the impact of AM processing on the shape memory properties of NiTi alloys using the Micro Wire and Arc Directed Energy Deposition (μ-WA-DED) technique in short circuit mode with a pioneering 0.3 mm pre-alloyed wire, focusing on increasing precision and control in the deposition process. The macroscopic morphology, microstructure, phase composition, phase-transformation temperatures, and mechanical properties of each deposited layer were analyzed. Results indicated austenite (B2) as the predominant phase, with retained martensite (B19′) and a reversible martensitic transformation (B2 ⇌ B19′) in the second layer. Mechanical characterization revealed variations in hardness (H) and elastic modulus (E) due to microstructural heterogeneity and composition. The first layer exhibited H = 3.8 GPa and E = 70 GPa, associated with the B2-NiTi phase, while higher values were obtained in the second layer, i.e., E = 100 GPa and H = 7 GPa. This study establishes for the first time the feasibility of NiTi alloy deposition with a 0.3 mm wire, setting a new standard for future research and applications in AM using μ-WA-DED.
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Entidade financiadora
Fundação para a Ciência e a Tecnologia
Programa de financiamento
OE
Número da atribuição
2021.05298.BD