Application of ICME to Optimize Processing of State-of-the-art Gear Steels in Additive Manufacturing

Additive manufacturing (AM) is a novel process of fabricating components in a layer-by-layer method under the control of computer-aided design (CAD) information, rather than by the traditional use of casting molds and forming dies. Integrated Computational Materials Engineering (ICME) methodologies are effective tools to reconfigure the materials development process and accelerate implementation of new higher performance alloys into demanding applications. QuesTek Innovations, an ICME leader, proposes to develop new DMLS AM techniques and finite element approaches to characterizing the effect of AM defects on material properties. C64 is a gear steel designed to be an upgrade over X53 via traditional-processing, and serves as a good transition candidate. In Phase I, QuesTek has demonstrated success in AM-processing of C64 steel through procurement and classification of C64 powder through commercial suppliers, optimization of deposition parameters in two separate AM systems, validation of tensile properties, and demonstrated response to case and core hardness after carburization and tempering. Throughout the program, QuesTek utilized its proven computational design methodology and experience in developing gear steels to define the process-structure-property relationships in AM-processing, ensuring a path forward for future success in Phase II. QuesTek has support from Bell Helicopter, GPI, Stratasys, and Carpenter Technology.