Data on the densification during sintering of binder jet printed samples made from water- and gas-atomized alloy 625 powders

Binder jet printing (BJP) is a metal additive manufacturing method that manufactures parts with complex geometry by depositing powder layer-by-layer, selectively joining particles in each layer with a polymeric binder and finally curing the binder. After the printing process, the parts still in the powder bed must be sintered to achieve full densification (A. Mostafaei, Y. Behnamian, Y.L. Krimer, E.L. Stevens, J.L. Luo, M. Chmielus, 2016; A. Mostafaei, E. Stevens, E. Hughes, S. Biery, C. Hilla, M. Chmielus, 2016; A. Mostafaei, Y. Behnamian, Y.L. Krimer, E.L. Stevens, J.L. Luo, M. Chmielus, 2016) [1-3]. The collected data presents the characterization of the as-received gas- and water-atomized alloy 625 powders, BJP processing parameters and density of the sintered samples. The effect of sintering temperatures on the microstructure and the relative density of binder jet printed parts made from differently atomized nickel-based superalloy 625 powders are briefly compared in this paper. Detailed data can be found in the original published papers by authors in (A. Mostafaei, J. Toman, E.L. Stevens, E.T. Hughes, Y.L. Krimer, M. Chmielus, 2017) [4].

Numerical Simulation of Twin-Twin Interaction in Magnetic Shape-Memory Alloys

Twin boundary motion is the mechanism that drives the plastic deformation in magnetic shape memory alloys (MSMAs), and is largely dependent on the twin microstructure of the MSMA. The twin microstructure is established during the martensitic transformation, and can be influenced through thermo-magneto-mechanical training. For self-accommodated and ineffectively trained martensite, twin thickness and magnetic-field-induced strain (MFIS) are very small. For effectively trained crystals, a single crystallographic domain may comprise the entire sample and MFIS reaches the theoretical limit. In this paper, a numerical simulation is presented describing the twin microstructures and twin boundary motion of self-accommodated martensite using disclinations and disconnections (twinning dislocations). Disclinations are line defects such as dislocations, however with a rotational displacement field. A quadrupole solution was chosen to approximate the defect structure where two quadrupoles represent an elementary twin double layer unit. In the simulation, the twin boundary was inclined to the twinning plane which required the introduction of twinning disconnections, which are line defects with a stress field similar to dislocations. The shear stress - shear strain properties of self-accommodated martensite were analyzed numerically for different initial configurations of the twin boundary (i.e. for different initial positions of the disconnections). The shear stress - shear strain curve was found to be sensitive to the initial configuration of disconnections. If the disconnections are very close to boundaries of hierarchically higher twins – such as is the case for self-accommodated martensite, there is a threshold stress for twin-boundary motion. If the disconnections are spread out along the twin boundary, twinning occurs at much lower stress.

Modeling magnetoelasticity and magnetoplasticity with disconnections and disclinations

The magneto-mechanical properties of magnetic shape-memory alloy single crystals depend strongly on the twin microstructure which is established during the martensitic transformation, and through thermo-magneto-mechanical training. For self-accommodated martensite, twin thickness and magnetic-field-induced strain are very small. For effectively trained crystals, a single twin may comprise the entire sample and magnetic-field-induced strain reaches the theoretical limit. Furthermore, the deformation of self-accommodated martensite is pseudo-elastic (magnetoelasticity) while the deformation of effectively trained crystals is plastic (magnetoplasticity). Twin microstructures of self-accommodated martensite were modeled using disclinations which are line defects such as dislocations, however with a rotational displacement field. The defect structure was approximated in a quadrupole solution where two quadrupoles represent an elementary twin double layer unit. The twin boundary was inclined to the twinning plane which required the introduction of twinning disconnections. The shear stress-shear strain properties of self-accommodated martensite were analyzed numerically for different initial configurations of the twin boundary (i.e. for different initial positions of the disconnections). The shear stress-shear strain curve is sensitive to the initial configuration indicating that disconnection nucleation is controlling the magneto-mechanical properties of self-accommodated martensite.

Giant magnetic-field-induced strains in polycrystalline Ni-Mn-Ga foams

The magnetic shape-memory alloy Ni-Mn-Ga shows, in monocrystalline form, a reversible magnetic-field-induced strain (MFIS) up to 10%. This strain, which is produced by twin boundaries moving solely by internal stresses generated by magnetic anisotropy energy, can be used in actuators, sensors and energy-harvesting devices. Compared with monocrystalline Ni-Mn-Ga, fine-grained Ni-Mn-Ga is much easier to process but shows near-zero MFIS because twin boundary motion is inhibited by constraints imposed by grain boundaries. Recently, we showed that partial removal of these constraints, by introducing pores with sizes similar to grains, resulted in MFIS values of 0.12% in polycrystalline Ni-Mn-Ga foams, close to those of the best commercial magnetostrictive materials. Here, we demonstrate that introducing pores smaller than the grain size further reduces constraints and markedly increases MFIS to 2.0-8.7%. These strains, which remain stable over >200,000 cycles, are much larger than those of any polycrystalline, active material.

Increasing magnetoplasticity in polycrystalline Ni-Mn-Ga by reducing internal constraints through porosity

Foams with 55% and 76% open porosity were produced from a Ni-Mn-Ga magnetic shape-memory alloy by replication casting. These polycrystalline martensitic foams display a fully reversible magnetic-field-induced strain of up to 0.115% without bias stress, which is about 50 times larger than nonporous, fine-grained Ni-Mn-Ga. This very large improvement is attributed to the bamboolike structure of grains in the foam struts which, due to reduced internal constraints, deform by magnetic-field-induced twinning more easily than equiaxed grains in nonporous Ni-Mn-Ga.