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In recent years, wire-arc directed energy deposition (waDED), which is also commonly known as wire-arc additive manufacturing (WAAM), has emerged as a promising new fabrication technique for magnesium alloys. The major reason for this is the possibility of producing parts with a complex geometry as well as a fine-grained microstructure. While the process has been shown to be applicable for Mg-Al-Zn alloys, there is still a lack of knowledge in terms of the influence of the WAAM process on the age-hardening response. Consequently, this study deals with the aging response of a WAAM AZ91 alloy. In order to fully understand the mechanisms during aging, first, the as-built condition was analyzed by means of high-energy X-ray diffraction (HEXRD) and scanning electron microscopy. These investigations revealed a fine-grained, equiaxed microstructure with adjacent areas of alternating Al content. Subsequently, the difference between single- and double-step aging as well as conventional and direct aging was studied on the as-built WAAM AZ91 alloy for the first time. The aging response during the various heat treatments was monitored via in situ HEXRD experiments. Corroborating electron microscopy and hardness studies were conducted. The results showed that the application of a double-step aging heat treatment at 325 °C with pre-aging at 250 °C slightly improves the mechanical properties when compared to the single-step heat treatment at 325 °C. However, the hardness decreases considerably after the pre-aging step. Thus, aging at lower temperatures is preferable within the investigated temperature range of 250-325 °C. Moreover, no significant difference between the conventionally aged and directly aged samples was found. Lastly, the specimens showed enhanced precipitation kinetics during aging as compared to cast samples. This could be attributed to a higher amount of nucleation sites and the particular temperature profile of the solution heat treatment. [ABSTRACT FROM AUTHOR]

The high flux combined with the high energy of the monochromatic synchrotron radiation available at modern synchrotron facilities offers vast possibilities for fundamental research on metal processing technologies. Especially in the case of laser powder bed fusion (LPBF), an additive manufacturing technology for the manufacturing of complex-shaped metallic parts, in situ methods are necessary to understand the highly dynamic thermal, mechanical, and metallurgical processes involved in the creation of the parts. At PETRA III, Deutsches Elektronen-Synchrotron, a customized LPBF system featuring all essential functions of an industrial LPBF system, is used for in situ x-ray diffraction research. Three use cases with different experimental setups and research questions are presented to demonstrate research opportunities. First, the influence of substrate pre-heating and a complex scan pattern on the strain and internal stress progression during the manufacturing of Inconel 625 parts is investigated. Second, a study on the nickel-base superalloy CMSX-4 reveals the formation and dissolution of γ' precipitates depending on the scan pattern in different part locations. Third, phase transitions during melting and solidification of an intermetallic γ-TiAl based alloy are examined, and the advantages of using thin platelet-shaped specimens to resolve the phase components are discussed. The presented cases give an overview of in situ x-ray diffraction experiments at PETRA III for research on the LPBF technology and provide information on specific experimental procedures.

Intermetallic γ-TiAl-based alloys are lightweight materials for high-temperature applications, e.g., in the aerospace and automotive industries. They can replace much heavier Ni-based alloys at operating temperatures up to 750 °C. Advanced variants of this alloy class enable processing routes that include hot forming. These alloys consist of three relevant crystallographic phases (γ-TiAl, α 2 -Ti 3 Al, β o -TiAl) that transform into each other at different temperatures. For thermo-mechanical treatments as well as for adjusting alloy properties required under service conditions, the knowledge of the thermal expansion behavior of these phases is important. Therefore, thermal expansion coefficients were determined for the relevant phases in a Ti-Al-Nb-Mo alloy for temperatures up to 1100 °C using high-energy X-ray diffraction.