Publications by authors named "Giulio Marchese"

This paper deals with the development and characterization of an Inconel 625 (IN625) reinforced with 2 wt.% of sub-micrometrical TiC particles produced by the laser powder bed fusion (LPBF) process. IN625 and IN625 2 wt.

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The microstructures of intermetallic γ-titanium aluminide (TiAl) alloys are subjected to a certain degree of Al evaporation when processed by electron beam powder bed fusion (EB-PBF). The magnitude of the Al-loss is mainly correlated with the process parameters, and highly energetic parameters produce significant Al evaporation. The Al-loss leads to different microstructures, including the formation of inhomogeneous banded structures, thus negatively affecting its mechanical performance.

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A new advanced dual-phase (DP) steel characterized by ferrite and bainite presence in equal fractions has been studied within this paper. The anisotropy change of this steel was assessed as a progressively more severe cold rolling process was introduced. Specifically, tensile tests were used to build a strain-hardening curve, which describes the evolution of this DP steel's mechanical properties as the thinning level increases from 20 to 70% with 10% step increments.

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This work focuses on the effect of different heat treatments on the Ti-6Al-4V alloy processed by means of electron beam melting (EBM). Super β-transus annealing was conducted at 1050 °C for 1 h on Ti-6Al-4V samples, considering two different cooling paths (furnace cooling and water quenching). This heat treatment induces microstructural recrystallization, thus reducing the anisotropy generated by the EBM process (columnar prior-β grains).

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Laser bed powder fusion (LPBF) is an additive manufacturing technology for the fabrication of semi-finished components directly from computer-aided design modelling, through melting and consolidation, layer upon layer, of a metallic powder, with a laser source. This manufacturing technique is particularly indicated for poor machinable alloys, such as Alloy 625. However, the unique microstructure generated could modify the resistance of the alloy to environment assisted cracking.

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Metal Additive Manufacturing and Laser Powder Bed Fusion (LPBF), in particular, have come forth in recent years as an outstanding innovative manufacturing approach. The LPBF process is notably characterized by very high solidification and cooling rates, as well as repeated abrupt heating and cooling cycles, which generate the build-up of anisotropic microstructure and residual stresses. Post-processing stress-relieving heat treatments at elevated temperatures are often required in order to release some of these stresses.

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The effect of microstructure on the susceptibility to selective corrosion of Alloy 625 produced by laser powder bed fusion (LPBF) process was investigated through intergranular corrosion tests according to ASTM G28 standard. The effect of heat treatment on selective corrosion susceptibility was also evaluated. The behavior was compared to commercial hot-worked, heat treated Grade 1 Alloy 625.

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The effect of aging treatment on Astroloy fabricated via hot isostatic pressing and subjected to super-, and sub- solvus solutioning has been investigated. The evolution of hardness and microstructural features were followed after each step of the treatment. Since this alloy is commonly subjected to a double aging treatment at two different temperatures, particular attention was given to the effectiveness of the first aging treatment compared to the second one.

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Aluminum alloys are key materials in additive manufacturing (AM) technologies thanks to their low density that, coupled with the possibility to create complex geometries of these innovative processes, can be exploited for several applications in aerospace and automotive fields. The AM process of these alloys had to face many challenges because, due to their low laser absorption, high thermal conductivity and reduced powder flowability, they are characterized by poor processability. Nowadays mainly Al-Si alloys are processed, however, in recent years many efforts have been carried out in developing new compositions specifically designed for laser based powder bed AM processes.

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Hastelloy X (HX) is a Ni-based superalloy which is employed to produce gas turbine and gas-cooled reactor sectors due to its outstanding oxidation resistance and high tensile strength at high temperatures. This alloy can be processed by laser powder bed fusion (LPBF) fabricating complex geometries in a single step. However, post-processing thermal treatments must be applied to generate a suitable microstructure for high-temperature applications.

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In this work, the characterization of the assembly of a steel shaft into a γ-TiAl part for turbocharger application, obtained using Electron Beam Welding (EBW) technology with a Ni-based filler, was carried out. The Ti-48Al-2Nb-0.7Cr-0.

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Hastelloy X (HX) is a Ni-based superalloy which suffers from high crack susceptibility during the laser powder bed fusion (LPBF) process. In this work, the microstructure of as-built HX samples was rigorously investigated to understand the main mechanisms leading to crack formation. The microstructural features of as-built HX samples consisted of very fine dendrite architectures with dimensions typically less than 1 µm, coupled with the formation of sub-micrometric carbides, the largest ones were mainly distributed along the interdendritic regions and grain boundaries.

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The mechanical properties and biocompatibility of titanium alloy medical devices and implants produced by additive manufacturing (AM) technologies - in particular, selective laser melting (SLM), electron beam melting (EBM) and laser metal deposition (LMD) - have been investigated by several researchers demonstrating how these innovative processes are able to fulfil medical requirements for clinical applications. This work reviews the advantages given by these technologies, which include the possibility to create porous complex structures to improve osseointegration and mechanical properties (best match with the modulus of elasticity of local bone), to lower processing costs, to produce custom-made implants according to the data for the patient acquired via computed tomography and to reduce waste.

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