Additive manufacturing (AM), also known as 3D printing or rapid prototyping, is gaining increasing attention due to its ability to produce parts with added functionality and increased complexities in ...geometrical design, on top of the fact that it is theoretically possible to produce any shape without limitations. However, most of the research on additive manufacturing techniques are focused on the development of materials/process parameters/products design with different additive manufacturing processes such as selective laser melting, electron beam melting, or binder jetting. However, we do not have any guidelines that discuss the selection of the most suitable additive manufacturing process, depending on the material to be processed, the complexity of the parts to be produced, or the design considerations. Considering the very fact that no reports deal with this process selection, the present manuscript aims to discuss the different selection criteria that are to be considered, in order to select the best AM process (binder jetting/selective laser melting/electron beam melting) for fabricating a specific component with a defined set of material properties.
This study addresses challenges in design and fabrication of thermally auxetic structures with zero thermal expansion (ZTE) using multi-material laser powder bed fusion. Planar 316L-CuCr1Zr lattices ...with re-entrant and triangular unit cells were designed, manufactured and tested. Introducing beam curvature as a new design parameter effectively reduces the coefficient of thermal expansion (CTE) compared to standard designs with straight struts. Curved beams act like non-linear springs and allow accommodating internal strains in the lattice. Despite the slight thermal expansion differences of CuCr1Zr and 316L, a curved-beam lattice is identified that mimics Invar's CTE up to 200 °C.
Understanding passivation behaviour of Hastelloy X (HX) superalloy by selective laser melting (SLM) is important to its anti-corrosion applications. The configuration, electronic properties, and ...electrochemical performance of passivation film on SLM-fabricated HX alloy surface were systematically compared with commercial wrought counterpart. The results indicated a thicker and more compact passivation film on the XOY surface (perpendicular to build direction) was attributed to its finer grains and higher density of low angle grain boundaries (LAGBs). These active sites increased the film growth rate by decreasing oxygen vacancy mobility in instantaneous nucleation process, leading to a superior corrosion resistance than wrought counterparts.
•The electrochemical behaviour of passivation film on SLM-fabricated Hastelloy X (HX) was investigated.•The SLM-fabricated HX surface formed a thicker and more compact passivation film with lower vacancy diffusion coefficient.•The refined grain size and a high density of low angle grain boundaries in SLM-fabricated HX contributed to this trend.•The SLMed XOY surface of HX alloy had the supreme corrosion resistance.
Selective laser melting (SLM) is widely gaining popularity as an alternative manufacturing technique for complex and customized parts. SLM is a near net shape process with minimal post processing ...machining required dependent upon final application. The fact that SLM produces little waste and enables more optimal designs also raises opportunities for environmental advantages. The use of aluminium (Al) alloys in SLM is still quite limited due to difficulties in processing that result in parts with high degrees of porosity. However, Al alloys are favoured in many high-end applications for their exceptional strength and stiffness to weight ratio meaning that they are extensively used in the automotive and aerospace industries. This study investigates the windows of parameters required to produce high density parts from AlSi10Mg alloy using selective laser melting. A compromise between the different parameters and scan strategies was achieved and used to produce parts achieving a density of 99.8%.
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The observation of sub-grained cellular features in additively manufactured (AM)/selectively laser melted (SLM) 316L stainless steel components has remained an interesting, though ...incompletely understood phenomenon. However, the recently observed correlation linking the presence of these features with significantly enhanced mechanical strength in SLM 316L materials has driven a renewed interest and effort toward elucidating the mechanism(s) by which they are formed. To date, the dominant hypothesis, cellular solidification followed by dislocation-solute entanglement, remains incompatible with the ensemble of reported observations from multiple independent studies. This effort offers direct evidence of a previously unrecognized interaction of phenomena, that, when acting in concert, give rise to this commonly observed substructure. These phenomena include SLM-induced intrinsic strain-aging, Cottrell atmosphere formation, and twin-boundary enhanced mass diffusion to structural defects. Furthermore, evidence is provided to support the proposed theory that the observed chemical heterogeneity coincident with dislocation cell structures is actually the result of local, strain energy density induced solid state diffusion.
Titanium alloys are an important material for several industries, despite being very energy intensive to produce. This study aims to maximize chip recyclability by adjusting the milling process and ...subsequent processing steps. The results show that the chip morphology determines the recyclability significantly. Also, a cleaning process is established to reduce chemical contamination. Based on the results a closed-loop material cycle for Ti–6Al–4V powder for additive manufacturing is presented. It is shown that the powder and material properties of printed samples are similar to those of conventional materials, while energy savings of up 77 % can be achieved.
In this paper, the recent progress on Ti6Al4V fabricated by three mostly developed additive manufacturing (AM) techniques-directed energy deposition (DED), selective laser melting (SLM) and electron ...beam melting (EBM)-is thoroughly investigated and compared. Fundamental knowledge is provided for the creation of links between processing parameters, resultant microstructures and associated mechanical properties. Room temperature tensile and fatigue properties are also reviewed and compared to traditionally manufactured Ti6Al4V parts. The presence of defects in as-built AM Ti6Al4V components and the influences of these defects on mechanical performances are also critically discussed.
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•Recent progresses in additively manufactured Ti6Al4V were reviewed.•Laser direct deposition, selective laser melting and electron beam melting were comparatively studied.•Processing-microstructure-tensile and fatigue properties relationship were established.•Effects of defects on mechanical properties were also addressed.
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•Critical internal defects in additive manufactured parts were detected by CT.•FE analysis of CT data is efficacious in modeling stress concentration factor.•Defects near to boundary ...cause a higher stress concentration factor.•Regional re-melting scanning strategy is proposed for fatigue applications.
Components manufactured by maturing additive manufacturing techniques like selective laser melting (SLM) find potential competence in several applications especially in automotive and aerospace industries as well as in medical applications like customized implants. The manufactured parts possess better, or at least comparable, yield strength and tensile strength values accompanied with a reduced fracture strain. Though their fatigue performance in the as-built condition is impaired due to surface roughness, it can be sufficiently improved by post-process surface treatments. Even then, there exists a high fatigue scatter due to remnant porosity. Characterization of remnant porosity is necessary for a reliable component design to be employed for cyclic applications. Computed tomography has been used in this study to evaluate the influence of porosity-incited stress concentration on the corresponding fatigue scatter. Microscopic analysis, tensile tests, fatigue tests with continuous load increase and constant amplitudes as well as finite element analysis have been used for this purpose. Critical pore characteristics and a modification in the process scanning strategy have been recommended so that the components can be reliably used in fatigue-loaded applications.
Additive manufacturing (AM), particularly Selective Laser Melting (SLM) has enabled development of lattice structures with unique properties. Through control of various parameters lattice structures ...can produce unique mechanical, electrical, thermal and acoustic properties, and have received much research attention. Despite the increasing volume of published data on the mechanical response of specific SLM lattice structures, there exists no overarching analysis. This work addresses this identified deficiency by providing a comprehensive summary of the experimental data reported on the mechanical response of SLM lattice structures. The design, fabrication and performance of SLM lattice structures are reviewed and the quality of data reported is analysed to inform best-practice for future studies. This comprehensive data summary enables meta-analysis of the reported mechanical performance of SLM lattice structures, providing insight into the bounds of their technical capabilities. Correlations were identified between the relative density and mechanical properties of many unit cell topologies consistent with the predictions of the Gibson-Ashby model, indicating its usefulness in describing and predicting the behaviour of SLM lattice structures. This review provides designers with a compiled resource of experimental data and design for AM tools to inform future design applications of SLM lattice structures and facilitates their further commercial adoption.
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•A review of the design, fabrication and mechanical performance of Selective Laser Melting (SLM) lattice structures.•Reported data on the mechanical performance and properties of a broad range of SLM lattice structures is compiled.•Meta-analysis of reported data allows insights into the applicability of the Gibson-Ashby model to SLM lattice structures.
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