Additive manufacturing of metallic components – Process, structure and properties

Freedom of design, mass customisation, waste minimisation and the ability to manufacture complex structures, as well as fast prototyping, are the main benefits of additive manufacturing (AM) or 3D printing. A comprehensive review of the main 3D printing methods, materials and their development in trending applications was carried out. In particular, the revolutionary applications of AM in biomedical, aerospace, buildings and protective structures were discussed. The current state of materials development, including metal alloys, polymer composites, ceramics and concrete, was presented. In addition, this paper discussed the main processing challenges with void formation, anisotropic behaviour, the limitation of computer design and layer-by-layer appearance. Overall, this paper gives an overview of 3D printing, including a survey on its benefits and drawbacks as a benchmark for future research and development.

Additive manufacturing (3D printing): A review of materials, methods, applications and challenges

Additive manufacturing of metals

Unlike conventional materials removal methods, additive manufacturing (AM) is based on a novel materials incremental manufacturing philosophy. Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser. The current development focus of AM is to produce complex shaped functional metallic components, including metals, alloys and metal matrix composites (MMCs), to meet demanding requirements from aerospace, defence, automotive and biomedical industries. Laser sintering (LS), laser melting (LM) and laser metal deposition (LMD) are presently regarded as the three most versatile AM processes. Laser based AM processes generally have a complex non-equilibrium physical and chemical metallurgical nature, which is material and process dependent. The influence of material characteristics and processing conditions on metallurgical mechanisms and resultant microstructural and mechanical properties of AM proc...

Laser additive manufacturing of metallic components: materials, processes and mechanisms

A study of the microstructural evolution during selective laser melting of Ti–6Al–4V

Parametric analysis of the selective laser melting process

A model for coupled radiation transfer and thermal diffusion is proposed, which provides a local temperature field. Single-line scanning of a laser beam over a thin layer of metallic powder placed on a dense substrate of the same material is studied. Both the laser beam diameter and the layer thickness are about 50 μm. The typical scanning velocity is in the range of 10―20 cm/s. An effective volumetric heat source is estimated from laser radiation scattering and absorption in a powder layer. A strong difference in thermal conductivity between the powder bed and dense material is taken into account. The above conditions correspond to the technology of selective laser melting that is applied to build objects of complicated shape from metallic powder. Complete remelting of the powder in the scanned zone and its good adhesion to the substrate ensure fabrication of functional parts with mechanical properties close to the ones of the wrought material. Experiments with single-line melting indicate that an interval of scanning velocities exists, where the remelted tracks are uniform. The tracks become "broken" if the scanning velocity is outside this interval. This is extremely undesirable and referred to as the "balling" effect. The size and the shape of the melt pool and the surface of the metallurgical contact of the remelted material to the substrate are analyzed in relation to the scanning velocity. The modeling results are compared with experimental observation of laser tracks. The experimentally found balling effect at scanning velocities above ∼20 cm/s can be explained by the Plateau―Rayleigh capillary instability of the melt pool. Two factors destabilize the process with increasing the scanning velocity: increasing the length-to-width ratio of the melt pool and decreasing the width of its contact with the substrate.

I. Smurov

Papers

Parametric analysis of the selective laser melting process

Model of Radiation and Heat Transfer in Laser-Powder Interaction Zone at Selective Laser Melting

Strategy of manufacturing components with designed internal structure by selective laser melting of metallic powder

Ceramic components manufacturing by selective laser sintering

Surface Morphology in Selective Laser Melting of Metal Powders