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

To up-grade selective laser melting (SLM) process for manufacturing real components, high mechanical properties of
final product must be achieved. The properties of a part produced by SLM technology depend strongly on the properties
of each single track and each single layer. In this study, effects of the processing parameters such as laser power,
scanning speed and powder layer thickness on the single tracks formation are analyzed. It is shown that, by choosing an
optimal technological window and appropriate strategy of SLM, it is possible to manufacture highly complex parts with
mechanical properties comparable to those of wrought material.

Strategy of fabrication of complex shape parts based on the stability of single laser melted track

Residual Stress in Metal Specimens Produced by Direct Metal Laser Sintering

In the present study, cellular lattice structures for implant applications are reported for the first-time incorporating copper directly by in-situ alloying in the laser powder bed fusion process. The aim to incorporate 3 at.% Cu into Ti6Al4V(ELI) is selected for improved antibacterial properties while maintaining appropriate mechanical properties. Previously, topologically optimized Ti6Al4V(ELI) lattice structures were successfully designed, manufactured and studied for implant applications. The development of a new alloy produced by in-situ alloying of elemental powder mixture of Ti6Al4V(ELI) and pure Cu powders was used here for the production of identical lattice structures with improved antibacterial properties. One of the same as-designed CAD models was used for the manufacturing of these lattices compared to previous work on pure Ti6Al4V(ELI) lattices, making direct comparison of mechanical properties possible. Similar manufacturability highlights the applicability of this alloying technique to other lattice designs. Microstructural characterization was performed by optical and electron microscopies, as well as microCT. Mechanical characterization was performed by means of compression tests and hardness measurements. Results showed that in-situ alloying with copper leads to the formation of localized Cu-rich regions, refinement of martensitic phase and the formation of CuTi2 intermetallic precipitates, which increased the hardness and strength of the material. Deviations in wall thickness between the as-designed and as-manufactured lattices led to anisotropy of the mechanical properties of the lattices. Higher compressive strength values were obtained when thicker walls were oriented along the loading direction. Nevertheless, alloying with Cu had a higher impact on the compressive strength of lattice structure than the wall thickness deviations. The direct in-situ alloying of copper in Ti6Al4V(ELI) is a promising route for direct manufacturing of antibacterial implants.

Mechanical behavior of in-situ alloyed Ti6Al4V(ELI)-3 at.% Cu lattice structures manufactured by laser powder bed fusion and designed for implant applications.

Direct metal laser sintering (DMLS) is a relatively new technology that is developing rapidly. Since DMLS material is created by melting/solidifying tracks and layers from powder, even building geometry can influence the mechanical properties. To certify a material, the testing specimens must be designed and manufactured according to the appropriate standards. Miniaturised tensile DMLS samples could be a good alternative for express quality control, and could reduce the cost of DMLS-specific testing. In this study, as-built and stress-relieved miniaturised tensile DMLS Ti6Al4V (ELI) specimens with different surface qualities were investigated. The fracture surfaces and mechanical properties of the mini-tensile specimens were analysed and compared with standard full-sized specimens also manufactured by DMLS. The obtained data showed the applicability of mini-tensile tests for the express analysis of DMLS objects if a correction factor is applied for the calculation of the load-bearing cross-section of the specimen.

http://www.scielo.org.za/pdf/sajie/v27n3/17.pdf

Validation of miniaturised tensile testing on dmls ti6al4v (eli) specimens

In Selective Laser Melting, the initial units produced are single tracks that overlap to create a single layer; from the sequence of layers, a 3D object is manufactured. The properties of the parts produced by SLM depend heavily on the properties of each single track and each layer formed by these tracks. This study evaluates the effect of processing parameters on the geometrical characteristics of single tracks manufactured from 17-4PH stainless steel powder. A single-mode continuous-wave ytterbium fibre laser was used to manufacture single tracks at laser powers in the range of 100-300 W with a constant spot size of ∼ 80μm. The single tracks produced were subjected to standard metallographic preparation techniques for further analysis with an optical microscope. Deep molten pool shapes were observed at low scan speeds, while shallow molten pool shapes were observed at high scan speeds. At higher laser power densities, under-cutting and humping effects were also observed. The dimensions of single tracks processed without powder generally decrease with increasing scan speed at constant laser power. However, the geometrical features of the single tracks processed with powder revealed pronounced irregularities believed to be caused by non-homogeneity in the deposited powder layer.

http://sajie.journals.ac.za/pub/article/download/1668/725

Igor Yadroitsev

Papers

Strategy of fabrication of complex shape parts based on the stability of single laser melted track

Residual Stress in Metal Specimens Produced by Direct Metal Laser Sintering

Mechanical behavior of in-situ alloyed Ti6Al4V(ELI)-3 at.% Cu lattice structures manufactured by laser powder bed fusion and designed for implant applications.

Validation of miniaturised tensile testing on dmls ti6al4v (eli) specimens

Evaluation of single tracks of 17-4ph steel manufactured at different power densities and scanning speeds by selective laser melting