Microstructural Analysis of Co-Cr Alloy Produced by Additive Manufacturing Process

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Precision ADM is a Canadian company that helps their customer companies to take advantage of advanceddigital manufacturing technologies, including additive manufacturing (AM), to produce innovative parts thatare stronger and lighter and at higher production rate and lower costs without undue burden to the environment.One of the key sectors that the company serves is the aerospace industry. Canadian aerospace industry is astrategically important contributor to the Canadian economy in terms of employment, innovation, productivityand trade. AM technology has shown potential to complement or replace some conventional manufacturingprocesses due to some of its many attractive benefits. It can be used to produce parts with complicated shapesthat are almost impractical to create by other manufacturing processes. It can also be used to producemonolithic components, thereby eliminating the need for assembling and joining, which also enables the easeand rapid introduction of new designs and customization. Moreover, for aerospace products, which often sufferfrom extremely low fly-to-buy ratio, the AM process can reduce costs in terms of improved time and materialutilization.This research project aims at understanding the underlying cause of porosity that forms during AM of anaerospace Co-Cr alloy by direct laser metal deposition method. The ultimate goal is the find an effectiveprocedure to minimize or completely eliminate the porosity, which is known to significantly degrademechanical properties and performance of AM products. A detailed microstructural study, through the use of asuite of microscopy and spectroscopy equipment at the University of Manitoba will be performed to analyzeand understand the cause(s) of the porosity. This will enable the development of an effective procedure foreradicating the problem, which will lead to effective AM process that lowers cost and enhance safety inaircrafts. Ultimately the project will aid Canada's competitiveness in advanced manufacturing technology.