Current Projects:

  • Modeling and experimental analysis on hybrid-additive manufacturing of metal matrix comosites 
  • Enhacing thermal conductivity of 316L stainless steel via laser powder bed fusion
  • Laser powder bed fusion and heat treatment of C22 Ni-based alloy 
  • Laser powder bed fusion of high entropy alloys (HEA)
  • Functionally graded Cu-Inconel alloy

Accomplished Projects:

  • Use of bimodal powder size distribution in powder bed of selective laser melting of 316L:  

Our objective is to improve the packing density of 316L stainless steel samples produced via SLM by using a bimodal powder size distribution. Primary powder of a larger size range is combined with a smaller particle size that fills the interstitial regions between the larger particles. The packing density and flowability of the mixed bimodal feedstock powder is determined by measuring tap density and Hausner ratio. Maximum tap density of the bimodal size distributions was up to 2% greater than the normally distributed powder. This project is funded by ATI, Oregon Metal Initiative (OMI) and Oregon Manufacturing Innovation Center (OMIC). Hannah is working on this project.

 

SLM paramaters optimization using 316L with bimodal powder size distribution as feedstock . 

Dr. Pasebani and Hannah are discussing on the role of laser processing parameters on the parts built by SLM process in OR Creator machine

  • Selective laser melting of 304 austenitic ODS steel for high temperature applications (Collaborative Research with Professor Brian Paul and Chih-hung Chang):

304L austenitic stainless steel is a structural material with superior mechanical properties, good corrosion, and oxidation resistance properties. Our objective is to embed nanoparticles to 304L matrix to improve high-temperature microstructural stability and mechanical properties through oxide dispersion mechanism. Our approach will overcome current challenges in conventional manufacturing of oxide dispersion strengthened (ODS) alloy (numerous steps such as mechanical alloying (MA) and hot consolidation making conventional manufacturing of ODS alloys costly, time-consuming and incapable of scale-up).This project is funded by US DOE and RAPID Institute. Milad is working on this project.

  • Binder jetting of Inconel 625 alloy (Collaborative Research with Professor Brian Paul):

In this project water atomized and gas atomized Inconel 625 powder are used in a Binder Jetting process. We are focusing on process optimization, investigation of the microstructure and measuring mechanical and corrosion properties at room and elevated temperatures. This project is funded by Oregon Business Development Department High Impact Opportunity Program. Sarah is working on this project.

  • Selective laser melting of Inconel 625 alloy and enhancing its thermal conductivity (functionally graded alloy):

In this project gas atomized Inconel 625 powder is used in a selective laser melting process. We are exploring processing-structure-property correlation. Our ultimate goal will be enhancing thermal conductivity of Inconel 625 using a second phase addition approach and creating a functionally graded Inconel 625 alloy via SLM process. Amir is working on this project.

  • High temperature corrosion and durability of alloys and coatings for combustion chamber (collaborative research with Professor MacCarty in Humanitarian Engineering):

Partners at the International Lifeline Fund (ILF) have asked OSU researchers to help develop a combustion chamber material that will withstand Haiti corrosive charcoal environment. The thermal cycling for daily cooking, abrasion from wood fuel, corrosive species in fuel stock, and high temperatures of combustion result in a harsh environment for most materials. The goal of this research is to investigate an array of potential alternative materials (such as graphite) and/or protective coatings (such as aluminum oxide on steel) that can increase the durability and lifetime of the combustion chambers for any type of biomass cook stoves. Nicolene is working on this project.

  • Selective laser melting of H13 tool steel for rapid tooling:

This project focuses on selective laser melting process optimization for H13 powder steel to create injection molding tools for plastic component production. In addition to SLM process parameters optimization for H13 tool steel powder, measuring dimensional accuracy and mechanical properties of 3D printed H13 component are other objectives of this study.  Michael is working on this project.

  • Selective laser melting of corrosion resistant ferrous alloys:

In this project, duplex stainless steel and maraging steel powder are considered as two corrosion resistant alloys to be used as powder feedstock in SLM process. Effect of selective laser melting process on mechanical  and corrosion properties of additively manufactured ferrous alloys will be studied in details. Greg is working on this project

  • Advanced manufacturing of high temperature Fe-based and Ni-based alloys for extreme environments (Pasebani’s PhD work)

Oxide dispersion strengthened nickel based alloys via spark plasma sintering:

Increasing the operating temperatures in coal-fired power plants, gas turbine inlets, and other high temperature structural components in order to improve their efficiency and economy will require new materials with high mechanical and creep strength, oxidation and corrosion resistance. Nickel based alloys are promising candidates for such applications due to their excellent corrosion resistance at elevated temperatures. Oxide dispersion strengthened (ODS) nickel-based alloys were developed via mechanical milling and spark plasma sintering (SPS) of Ni–20Cr powder with additional dispersion of 1.2 wt% Y2O3 powder. Furthermore, 5 wt% Al2O3 was added to Ni–20Cr–1.2 Y2O3 to provide composite strengthening in the ODS alloy. Adding 1.2 wt% Y2O3 to Ni–20Cr matrix significantly reduced the grain size due to dispersion strengthening effect of Y2O3 particles in controlling the grain boundary mobility and recrystallization phenomena.  A high compression yield stress obtained at 800 °C for Ni–20Cr–1.2Y2O3–5 Al2O3 alloy was attributed to a combined effect of dispersion and composite strengthening. This work was support by the University Coal Research Program of the U.S. Department of Energy (DOE) via a grant managed by the National Energy Technology Laboratory (NETL).

Enhanced yield strength in Ni–20Cr–1.2 Y2O3–5 Al2O3 (wt.%) due to dual scale particle strengthening

 

TEM micrographs of spark plasma sintered Ni-20Cr, Ni-20Cr-1.2 Y2O3 and Ni–20Cr–1.2 Y2O3–5 Al2O3 (wt.%)

Lanthana-bearing nanostructured ferritic steels manufactured via spark plasma sintering

Thermally stable nanofeatures with high number density are expected to impart excellent high temperature strength and irradiation stability in nanostructured ferritic steels (NFSs) which have potential applications in advanced nuclear reactors. A lanthana-bearing NFS (14LMT) was developed via mechanical alloying and spark plasma sintering (SPS). The spark plasma sintered samples were irradiated by Fe2+ ions to 10, 50 and 100 dpa at 30 °C and 500 °C. Overall morphology and number density of the nanofeatures remained unchanged after irradiation. Average radius of nanofeatures in the irradiated sample (100 dpa at 500 °C) was slightly reduced.  Other microstructural features like grain boundaries and high density of dislocations also provided defect sinks to assist in defect removal.

Three dimensional (3-D) APT reconstruction maps of the 14LMT alloy after SPS at 950 °C for 45 min  

TEM micrographs of 14LMT alloy irradiated at 500 C up to100 dpa 

Microstructural stability of a self-ion irradiated lanthana-bearing nanostructured ferritic steel

A preliminary investigation of high dose ion irradiation response of a lanthana-bearing nanostructured ferritic steel processed via spark plasma sintering

Pasebani Google Scholar