다중혈관 관상동맥 환자에서 y-문합을 이용하여 양쪽 내흉동맥만을 사용한 우회술의 조기 성적

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

Reduction of micro-cracking in nickel superalloys processed by Selective Laser Melting: A fundamental alloy design approach

Purpose – Obtaining the required part top surface roughness and side roughness is critical in some applications. Each of these part properties can often be improved to the detriment of the other during selective laser melting (SLM). The purpose of this paper is to investigate the selective laser melting of Inconel 625 using an Nd:YAG pulsed laser to produce thin wall parts with an emphasis on attaining parts with minimum top surface and side surface roughness.Design/methodology/approach – A full factorial approach was used to vary process parameters and identify a usable Inconel 625 processing region. The effects laser process parameters had on the formation of part surface roughness for multi‐layer parts were examined. Processing parameters that specifically affected top surface and side roughness were identified.Findings – Higher peak powers tended to reduce top surface roughness and reduce side roughness as recoil pressures flatten out the melt pool and reduce balling formation by increasing wettabilit...

Top surface and side roughness of Inconel 625 parts processed using selective laser melting

During the Selective Laser Melting (SLM) process large temperature gradients can form, generating a mismatch in elastic deformation that can lead to high levels of residual stress within the additively manufactured metallic structure. Rapid melt pool solidification causes SLM processed Ti6Al4V to form a martensitic microstructure with a ductility generally lower than a hot working equivalent. Currently post-process heat treatments can be applied to SLM components to remove in-built residual stress and improve ductility. This study examined the effect of scanning strategy (scan vector lengths and scan vector rotation) and rescanning strategy on residual stress formation and mechanical properties of SLM Ti6Al4V parts. 90° alternating scanning strategy resulted in the lowest residual stress build-up for SLM Ti6Al4V parts built on both the standard and modified Renishaw platforms using a modulated Nd-YAG fiber laser. Scanning strategy did not show any direct correlation with mechanical properties. Re-scanning with 150% energy density resulted in 33.6% reduction in residual stress but the effect on mechanical properties was detrimental and samples failed prematurely. The study was based on detailed experimental analysis along with Finite Element simulation of the process using ABAQUS to understand the underlying physics of the process.

Effect of scanning strategies on residual stress and mechanical properties of Selective Laser Melted Ti6Al4V

During the Selective Laser Melting (SLM) process large temperature gradients can form, generating a mismatch in elastic deformation that can lead to high levels of residual stress within the additively manufactured metallic structure. Rapid melt pool solidification causes SLM processed Ti6Al4V to form a martensitic microstructure with a ductility generally lower than a hot working equivalent. Post-process heat treatments can be applied to SLM components to remove in-built residual stress and improve ductility. The use of high temperature pre-heating during an SLM build can assist in reducing thermal gradients, enable a more controlled cooling with the possibility to control/tailor as-built mechanical properties. In this work a high temperature SLM powder bed capable of pre-heating to 800 °C is used during processing of Ti6Al4V feedstock. The effect of powder bed temperature on residual stress formation, microstructure and mechanical properties was investigated. It was found that increasing the bed temperature to 570 °C significantly reduced residual stress formation within components and enhanced yield strength and ductility. This pre-heating temperature enabled the decomposition of α ′ martensitic microstructure into an equilibrium α+β microstructure. At 570 °C the yield strength and elongation of components was improved by 3.2% and 66.2% respectively.

In-situ residual stress reduction, martensitic decomposition and mechanical properties enhancement through high temperature powder bed pre-heating of Selective Laser Melted Ti6Al4V

Kamran Mumtaz

Papers

Reduction of micro-cracking in nickel superalloys processed by Selective Laser Melting: A fundamental alloy design approach

Top surface and side roughness of Inconel 625 parts processed using selective laser melting

Effect of scanning strategies on residual stress and mechanical properties of Selective Laser Melted Ti6Al4V

In-situ residual stress reduction, martensitic decomposition and mechanical properties enhancement through high temperature powder bed pre-heating of Selective Laser Melted Ti6Al4V

Selective Laser Melting of thin wall parts using pulse shaping