Posters

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Ramzy Abou-Zeid - Session 5 (Wed 09.00-10.55)

University of Manchester

Microstructural characterisation of defects formed during additive repair of nickel superalloy INC718

Nickel superalloys are used in aerospace for their excellent mechanical performance and corrosion resistance at elevated temperatures, like those found in aeroengines. Additive repair techniques such as Direct Energy Deposition (DED) are being developed to allow for the repair of these components in order to prolong the service life of these component, reducing maintenance costs.

In this study, a nickel superalloy aero-component repaired using the DED technique will be subjected to a microstructural examination to determine the origin of a particular defect that arose during the repair process, which had not been observed in previous repairs following similar parameters.

Grey Bell - Session 5 (Wed 09.00-10.55)

University of Sheffield

Analysis of the Current UK Scrap Landscape: Challenges and Opportunities

UK steel manufacturing is changing due to government targets to reduce emissions by over 95% by 2050, driving towards decarbonisation, and net-zero emissions. Emissions produced via the EAF route are less than the BF/BO route, so this is the direction for the UK integrated steel producers. An EAF can use three times the scrap of a BOF, so increasing production in the EAF route needs a robust and secure supply of high quality scrap. The aim is to research and analyse scrap procurement, sorting scrap, scrap use in current BF/BOF steelmaking, and challenges and solutions in producing automotive and packaging steel by EAF.

Kate Bowers - Session 5 (Wed 09.00-10.55)

University of Sheffield

Understanding the effects of Die Geometry and Wheel Speed on Grain Size of Commercially Pure CONFORM Copper Wire

Investigation into the processing parameters of commercially pure copper feedstock through the CONFORM machine, with the aim to understand the effects of die geometry and wheel speed on grain size of the extruded product. This initial investigation will use solid feedstock to identify tooling requirements and processing parameters to produce microstructure, mechanical properties and surface texture comparable to material processed commercially. The second stage of the project will be to investigate the effect of using a recycled feedstock (wire) and identify the effect on microstructure, mechanical properties and surface texture. This analysis will include comparison of the data from the FEM simulations and physical metallurgy of the samples produced. 

Olivia Broadbent-Clark - Session 1 (Tue 09.00-10.55)

University of Manchester

Microstructural characterisation of initial processing steps in production of recycled can-body aluminium

Aluminium is widely used in the packaging industries mainly due to its high-strength-to-weight ratio, low density, and corrosion resistance properties. Despite the many advantages of using recycled aluminium, issues associated with the presence of impurities limit applications. These impurities influence the material’s properties, thereby affecting its response to various manufacturing processes.

This project will focus on the comparison between standard 3XXX series aluminium alloy and highly recycled 3XXX series aluminium alloy. The objective is to determine the difference between standard and highly recycled variants of an aluminium alloy by understanding the relationship between recycled content, process conditions, and microstructure.

Sydney Coates - Session 1 (Tue 09.00-10.55)

University of Manchester

Understanding coldwork needed for recrystallisation of 316 LPBF material and it's affect on the material's performance in PWR primary water

Co-authors: Dr. Fabio Scenini and Dr. Ed Pickering both the University of Manchester

With a rise in cases of intergranular stress corrosion cracking (IGSCC) occurring within normal free-flowing primary water in a pressurised water tank, research into understanding the critical stresses that result in crack initiation is required. The aim is to understand the mechanistic effect of additive manufacturing on stress corrosion cracking initiation. Mechanical testing is done on material’s subjected to different levels of coldwork and heat treatments to fully recrystallise the material’s microstructure. The microstructure’s corrosion resistance is analysed through preliminary pitting tests. Microstructural analysis both before and after pitting are analysed using SEM to understand the microstructure’s affect on performance.

Tom Cole - Session 5 (Wed 09.00-10.55)

University of Sheffield

Investigating the Effects of Processing on Short-Range Order and Physical Properties of Ni-33at.%Cr

Co-authors: E. J. Palmiere (University of Sheffield), H. Y. Playford (ISIS Neutron Muon Source), L. R. Owen (University of Sheffield)

The existence of Short-range order (SRO) in alloys has previously been linked to a host of metallurgical phenomena, including solution strengthening, electrical and magnetic properties. Recent advancements in Total Scattering Techniques have provided a novel method to explore the effects of local ordering, however a gap still exists between local structure measurements and practical observations. Deviations in electrical resistivity and mechanical behaviour have long been used to infer crystallographic changes attributed to SRO, with material processing known to greatly influence this. Of particular interest is the ordering of Ni-Cr due to its presence in nickel superalloys and known propensity to form an ordered Ni₂Cr superlattice. The present work looks to identify the changes in physical properties of Ni-33at.%Cr as a result of different thermomechanical processing, such to infer the presence of local ordering.

Lucas Cook - Session 5 (Wed 09.00-10.55)

University of Sheffield

Analysis of the Relationship Between Wheel Speed and Grain Size of Aluminium Wire Produced Via the ConformTM Process

Co-authors: William Pulfrey - University of Sheffield, Eric Goodall - University of Sheffield, Martin Jackson - University of Sheffield

The ConformTM process, established in the early 1970s, recycles wire or rod feed stocks into usable parts from mainly aluminum or copper sources. Research suggests its potential but lacks understanding of the mechanical process involved during wire production. This study aims to advance aluminum powder extrusion via ConformTM using FEM to correlate production parameters such as wheel speed and temperature with wire microstructure. This will help to develop the ConformTM process into a industrially applicable process for the recycling of waste powders from additive manufacturing into wire that can be reused in the additive manufacturing sector.

Grace Fidler - Session 1 (Tue 09.00-10.55)

University of Manchester

Observation of retained austenite decomposition using dilatometry and correlative microscopy

Heat treatments of SA508 Gr.3 steel (a popular RPV steel) can affect the final microstructure, its toughness and service lifetime (of 40 years or more). Understanding the impact of quench rates on retained austenite is important as it can influence the later tempering behaviour. In this work, heat treatments are simulated with quenching dilatometry and the microstructures before and after heat treatment are imaged using SEM to observe the decomposition of austenite islands before and after tempering. This austenite content, as determined by SEM is further validated by XRD to understand the retained austenite decomposition conditions and mechanisms.

Dillon Frith - Session 1 (Tue 09.00-10.55)

University of Sheffield

Force Feedback Analysis of Ti-6246

Force Feedback is a non-destructive evaluation technique for titanium alloys and upstream forged conditions. The main purpose of the force feedback approach is to detect deleterious regions in the microstructure of forged material that may be liable to performance hindering features when in-service. From the force feedback data, a microstructural twin can be digitally created.

Thomas Gillick - Session 3 (Tue 14.00-15.40)

Dublin City University

Analysing residual stresses in nickel-titanium parts produced from laser powder bed fusion by utilising beam mechanics equations

This project will utilise beam mechanics equations to determine the residual stresses that have accumulated in nickel-titanium beam samples during printing. This will be completed by measuring the warpage that occurs to the samples prior to and following removal from the base plate. These samples will be fabricated using laser powder bed fusion. During printing, several parameters including the part orientation in relation to the argon gas flow, the scanning angle increment per layer, as well as the hatch spacing, will also be investigated to determine their effect on the residual stresses in the beam samples.

Meris Ikiz - Session 6 (Wed 11.15-12.55)

Dublin City University

Investigation of the bond strength of laser-textured interference-fit joints

In this mini project, laser surface texturing will be applied to 316L stainless steel for the production of high-end interference fit fasteners. The research introduces a surface laser texturing approach to enhance both the surface roughness and bond strength control of press-fit connections. Using a pulsed CO2 laser beam the cylindrical pins with a diameter of 10 mm 316L stainless steel will be textured along a 10 mm length, with the laser beam focused millimeter beneath the surface. Laser processing parameters specifically the laser beam power, the pulse repetition frequency, and the overlap between scan tracks will be used to control the pin surface morphology and dimensions.

Ian Kiernan - Session 6 (Wed 11.15-12.55)

Dublin City University

Measurement of Sliotar Coefficient of Restitution at High Speed

The main aim of this mini project is to assess the high speed performance of the current licensed sliotars used by the senior intercounty squads in hurling. This assessment will allow us to analyse the sliotar performance data of a high speed test and translate this into the performance when looking at the hurley/sliotar impact interaction which will be one of the main measures of assessment of the mechanical performance and properties of an ash hurley in the upcoming full PhD project Hurley/Sliotar
Impact Interactions – a system for automated measurement and assessment. Currently the official COR is gathered using a standardised low speed test, used for balls in many sports. The COR data gathered from this mini project will also be used to allow future comparison between low and high speed results.

Jack Krohn - Session 2 (Tue 11.15-12.55)

University of Sheffield

An Investigation into the Manufacturing Route of a FAST produced Functionally Graded, Titanium Alloy Composite Sandwich Structure

This project will investigate the feasibility of manufacturing a functionally graded, composite titanium alloy structure using powder metallurgy methods, with applications in the aerospace industry. This project will be used to compare and assess various manufacturing processes with powder metallurgy routes to produce this composite structure, and the resultant part properties will be explored. Field Assisted Sintering Technology (FAST) will be utilised to produce consolidated Titanium alloy billets. The billets will then undergo a range of forming and post processes such as hot rolling and superplastic forming, and the resultant microstructure shall be investigated.

Eamonn Lawlor - Session 1 (Tue 09.00-10.55)

University of Manchester

Effect of stress concentrations on Ti64 under cold creep

Co-authors: Prof. Philip Prangnell - University of Manchester, Prof. Joao Quinta da Fonseca - University of Manchester, Benjamin Dod - Airbus

Cold dwell fatigue (CDF) is a phenomenon which occurs in titanium and titanium alloys under cyclic trapezoidal loading where the maximum tensile stress is held for a period of time. This occurs at room temperature and can result in a fatigue life debit in components. This project investigates the effect of notches, which introduce a stress concentration, by subjecting notched and unnotched samples to room temperature creep tests. The resulting creep curves from the tests will be assessed as well as the fracture surface via microscopy and the crystallographic texture through electron backscatter diffraction (EBSD).

Jozef McGowan - Session 2 (Tue 11.15-12.55)

University of Sheffield

Analysing the Tool Wear and Microstructural Damage When Using Uncoated Cemented Carbide Tools of Differing Grades for the Milling of Ti64 Samples Manufactured Using Differing Processing Routes

Co-authors: Prof. Martin Jackson - University of Sheffield, Dr. Alexander Graves - Sandvik Coromant

This project aims to study the tool wear and microstructural damage as well as the cobalt diffusion which occurs when different grades of tungsten carbide tool are used to face mill Ti-6Al-4V samples manufactured from different processing routes. To do this, a parametric study will be carried out using tools of differing binder content to face mill Ti-6Al-4V which have been forged, FAST forged and wire arc additive manufactured. In addition to this, the cutting response force will be analysed using in spindle and plate dynamometers. As the milling trials can not take place until June, extensive work will be carried out in characterising of the tools and workpieces and carrying out diffusion couples on the tool material and Ti-6Al-4V.

Xavier Olojez - Session 3 (Tue 14.00-15.40)

University of Manchester

Slip activity in Ti-6Al-4V under cold creep conditions

Co-authors: D.Lunt - University of Manchester, P. Withers - University of Manchester, J. Q. Fonseca - University of Manchester

Cold dwell fatigue is a time-dependent degradation process that occurs in titanium aero-engines under cyclic loadings with dwell periods at peak stress under the yield strength of the titanium, these dwell periods are associated with specific periods such as landing or take off. The time-dependent component of Cold dwell fatigue has been identified to be cold creep, i.e. creep at room temperature. During the present work, cold creep was studied in Ti–6Al–4V using in-situ High-Resolution Digital Image Correlation. A study of the strain localisation in terms of the active slip systems at different stresses was carried out along with a baseline characterisation of the alloy using EBSD.

Yvonne Omowunmi-Kayode - Session 6 (Wed 11.15-12.55)

Dublin City University

Laser Texturing of Ti-6Al-4V for enhanced anti-biofouling and hydrophobic properties

Laser texturing the surface of Ti-6Al-4V using a femtosecond laser is investigated. Laser texturing is a surface modification method that alters the surface of a material which affects its surface morphology and surface chemistry. Both the surface morphology and surface chemistry have a direct effect on the wettability of a surface and its ability to prevent or decrease the development of surface fouling. The properties investigated are surface morphology, surface chemistry, surface roughness, surface wettability and anti-biofouling efficiency. The main aim of this study is to produce micro-scaled textured surfaces which have optimised anti-biofouling and hydrophobic properties.

Mostafa Salem - Session 2 (Tue 11.15-12.55)

University of Sheffield

Predicting the Distribution of Nanopores in SLM

Co-author: Hector Basoalto - University of Sheffield

High-alloy materials like CM247LC are favored for demanding high-temperature, high-stress applications due to their stability at elevated temperatures. However, producing parts through Selective Laser Melting (SLM) remains challenging, primarily due to the poor weldability of such alloys. The exact mechanism behind cracking during SLM is still debated, making crack-free part production elusive. This study proposes a phase-field-based approach to model CM247LC dendritic solidification during SLM. It explores nanovoid formation in interdendritic regions and conducts parametric studies on cooling rate and temperature gradient effects on nanopore characteristics. Additionally, an analytical expression for Allen-Cahn mobility is formulated, and a linear stability analysis aids in understanding interface instability and dendrite formation regions.

Ajai Sankar - Session 3 (Tue 14.00-15.40)

University College Dublin

A Comprehensive Investigation into the Microstructural Evolution and Fatigue Performance of LPBF Ti-6Al-4V Post Hot Isostatic Pressing (HIP)

Additive manufacturing, particularly Laser Powder Bed Fusion (LPBF), has emerged as a revolutionary technique for fabricating complex structures, such as lattice components, using materials like Ti-6Al-4V. This mini-project aims to investigate synergistic effects of Hot Isostatic Pressing (HIP)combined with intricate lattice structures on porosity control, aiming to enhance microstructural characteristics and fatigue performance of the Ti-6Al-4V components. The study encompasses a comprehensive characterisation of the microstructure using advanced techniques like X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and optical microscopy. Fatigue testing will be conducted to evaluate the material’s performance. Additionally, in situ XRD will be employed to study the phase evolution and transformation. The findings aim to contribute to the understanding of LPBF Ti-6Al-4V components, and how the approach could deliver microstructure and performance comparable to conventionally manufactured parts.

Riccardo Sorrill - Session 2 (Tue 11.15-12.55)

University College Dublin

The impact of shape factors on the AM print morphology using in-process monitoring

The objective of this mini-project is to evaluate the use of in-process monitoring tools as a route to assist in the optimisation of print processing conditions during the printing of geometrically complex tool steel parts. The in-process analysis will be conducted by utilising both optical emission and image data acquired during the printing. The investigation will focus on complex tubular structures, paying close attention to both the vertical and curved surfaces. The goal is to ensure uniformity in the printed structures, particularly at edges compared to the bulk alloy. The printed parts will be characterized to determine their morphology, grain structure, and porosity.

Richard Thomson - Session 2 (Tue 11.15-12.55)

University of Sheffield

Review of computational methods of analysing rail wear

Co-authors: David Fletcher (The University of Sheffield), Adam Wilby (British Steel), Jacob Corteen (British Steel)

Computational methods of predicting rail wear, such as the brick and layer models, will be reviewed alongside underlying mechanisms of wear debris generation (plastic damage accumulation, fracture, free particle formation). Analysis of worn samples, which will have undergone testing using the SUROS2 twin disc machine, will generate evidence using nanoindentation, microscopy, and surface roughness measurement. Computational methods and physical evidence will then be compared, and the findings from this will enable conclusions to be drawn regarding the positive and negative aspects of each method, and its suitability for a variety of contact conditions that the rail may serve in use.

Andrea Villano - Session 6 (Wed 11.15-12.55)

University College Dublin

Application of 5G network as data transfer tool in Selective Laser Melting for metal printing

Main Supervisor: Prof. Denis Dowling - Department of Material Engineering (UCD)
Second Supervisors: Prof. Fatemeh Golpayegani - Department of Computer Science (UCD), Dr. Cathal Hoare - postdoctoral researcher in Data Management and Analytics (I-Form)

The aim of this project is to study the feasibility of implementing 5G network and edge computing as tools for enhancing the data transfer, processing and operator feedback efficiency during additive manufacturing, through the handling of in-process meltpool data for laser powder bed fusion (L-PBF) printed steel parts. The InfiniAM system will be used for data acquisition through optical emission and image sensors. Anomaly detection will be performed with the STRAY algorithm. The I-Form Recommender System will be used for data processing and operator feedback process. 5G and edge computing performances will be compared with the currently established architecture in the matter of data transmission loads and speed.

Matt Williamson - Session 3 (Tue 14.00-15.40)

University of Manchester

Decoupling the Influence of Creep on Initiation of Environmentally Assisted Cracking

Co-authors: Timothy L. Burnett (Manchester), Philip B. Prangnell (Manchester), Zak Barrett (Airbus), Nick Byers (Airbus), Matthew E. Curd (Manchester), Juhi Srivastava (Manchester)

3rd gen. 7xxx series aluminium alloys are used across a wide range of transport applications due to their high strength and low weight; however, these alloys are susceptible to Hydrogen Embrittlement-related Environmentally Induced Cracking (H-EIC) when exposed to warm humid air. This paper aims to improve our understanding of H-EIC by investigating the significance of low temperature creep on crack initiation in 7xxx series aluminium. This will be achieved by comparing four-point bend tests in humid air with the effect of pre-loading samples in dry air until creep is exhausted before introducing the environment.

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