3D printing of shape memory Alloys for complex architectures of smart structures

Shape Memory Alloys (SMA) are materials used to design smart structures with intrinsic functional properties and improved efficiency. This is a key aspect of aerospace industry and makes SMA good candidates in this field. One of the most widespread SMA is the equiatomic NiTi alloy which, however, has the strong limitation of poor machinability, so only simple shapes can be obtained. Additive Manufacturing processes allow to overcome this limit and to design complex shapes. Compared to other metallic materials, the optimization of the process for NiTi alloy is complicated because, beside mechanical properties and presence of defects, considerable attention needs to be dedicated to the material functionality. The high temperatures involved in the additive process significantly affect the material properties due to possible evaporation of Ni and formation of precipitates that enable a shift of the phase transformation temperatures. This paper is focused on the optimization of the process parameters of the NiTi alloy printed through the Laser Powder Bed Fusion (L-PBF) to ensure optimal pseudo-elastic behaviour, which is essential for the design of structural dampers. This was accomplished starting from simple structures and then designing a damper that couples the pseudoelasticity of NiTi with load support capacity. The L-PBF is a powder-bed technique that selectively melts layers of micrometric metal powder. A pseudoelastic NiTi powder with 50.8 at. % of Ni content was selected and characterized through scanning electron microscope (SEM) and observations connected to an Energy Dispersive X-ray Spectroscopy (EDX) probe. After that, some cubic samples were manufactured, with the dimension of 3 x 3 x 15 mm3. A set of different laser powers and scanning speeds were used to find the set of process parameters that optimize the functional properties of the printed parts. Near fully dense specimens with density higher than 99.5% were selected for further investigations. Differential scanning calorimetry (DSC) and mechanical tests were performed on as-built and heat-treated samples. Quasi-static mechanical tests were accomplished in compression mode, at different strains, up to 8%. It was observed that the residual strain for cyclic loading at 4% is lower than 1%, so good recovery of the deformation was shown. Moreover, numerical analyses that mimic the pseudoelastic behaviour in compression tests were implemented. Finally, the best set of parameters was selected on the basis of the material's ability to recover deformations and its loss factor.