Additive manufacturing of metallic components – Process, structure and properties

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting

https://research.birmingham.ac.uk/portal/files/20155386/Accepted_manuscript.pdf

On the role of melt flow into the surface structure and porosity development during selective laser melting

The present paper systematically investigated the influence of solution and artificial aging heat treatments on the microstructures and mechanical properties of SLM-produced AlSi10Mg alloy parts. Due to the high cooling rate of SLM, an ultrafine eutectic microstructure in the as-built samples is characterized by spherical nano-sized network eutectic Si embedded in the Al matrix, which gives rise to significantly better tensile properties and Vickers micro-hardness. The solubility of Si atom in the Al matrix of as-built SLM samples is calculated to be 8.89 at%. With the increase in the solution temperature, the solubility decreases rapidly. The artificial aging causes the further decrease of the solubility of Si atoms in the Al matrix. Upon solution heat treatment, Si atoms are rejected from the supersaturated Al matrix to form small Si particles. With increasing the solution temperature, the size of the Si particles increases, whereas their number decreases. After artificial aging, the Si particles are further coarsened. The variation in size of Si particles has a significant influence on the mechanical properties of the AlSi10Mg samples. The tensile strength decreases from 434.25±10.7 MPa for the as-built samples to 168.11±2.4 MPa, while the fracture strain remarkably increases from 5.3±0.22% to 23.7±0.84% when the as-built sample is solution-treated at 550 °C for 2 h. This study indicates that the microstructure and mechanical properties of SLM-processed AlSi10Mg alloy can be tailored by suitable solution and artificial aging heat treatments.

Effect of heat treatment on AlSi10Mg alloy fabricated by selective laser melting: Microstructure evolution, mechanical properties and fracture mechanism

AlSi10Mg cellular lattice structures have been fabricated by selective laser melting (SLM) using a range of laser scanning speeds and powers. The as-fabricated strut size, morphology and internal porosity were investigated using optical microscopy (OM), scanning electron microscopy (SEM) and X-ray microtomography (micro-CT) and correlated to the compressive properties of the structure. Strut diameter was found to increase monotonically with laser power while the porosity was largest at intermediate powers. Laser scanning speed was found to thicken the struts only at slow rates while the porosity was largest at intermediate speeds. High speed imaging showed the melt pool to be larger at high laser powers. Further the melt pool shape was found to vary cyclically over time, steadily growing before becoming increasingly instable and irregularly shaped before abruptly falling in size due to splashing of molten materials and the process repeating. Upon compressive loading, lattice deformation was homogeneous prior to the peak stress before falling sharply due to the creation of a (one strut wide) shear band at around 45° to the compression axis. The specific yield strength expressed as the yield stress/(yield stress of the aluminium × relative density) is not independent of processing conditions, suggesting that further improvements in properties can be achieved by process optimisation. Lattice struts failed near nodes by a mixture of ductile and brittle fracture.

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Influence of processing conditions on strut structure and compressive properties of cellular lattice structures fabricated by selective laser melting

A three-dimensional, transient, multiscale model of the VAR process is presented, allowing novel simulations of the influence of fluctuations in arc behavior on the flow and heat transfer in the molten pool and the effect this has on the microstructure and defects. The transient behavior of the arc was characterized using the external magnetic field and surface current measurements, which were then used as transient boundary conditions in the model. The interactions of the magnetic field, turbulent metal flow, and heat transfer were modeled using CFD techniques and this “macro” model was linked to a microscale solidification model. This allowed the transient fluctuations in the dendritic microstructure to be predicted, allowing the first coupled three-dimensional correlations between macroscopic operational parameters and microstructural defects to be performed. It was found that convection driven by the motion of the arc caused local remelting of the mushy zone, resulting in variations in permeability and solute density. This causes variations in the local Rayleigh number, leading to conditions under which freckle solidification defects will initiate. A three-dimensional transient tracking of particle fall-in was also simulated, enabling predictions of “white spot” defects via quantification of the trajectory and dissolution of inclusions entering the melt.

A Multiscale 3D Model of the Vacuum Arc Remelting Process

A multi-scale 3D model of the vacuum arc remelting process

Corrigendum to ??Influence of processing conditions on strut structure and compressive properties of cellular lattice structures fabricated by selective laser melting?? [Mater. Sci. Eng. A 628(2015)188?197]

Mark Ward

Papers

On the role of melt flow into the surface structure and porosity development during selective laser melting

Influence of processing conditions on strut structure and compressive properties of cellular lattice structures fabricated by selective laser melting

A Multiscale 3D Model of the Vacuum Arc Remelting Process

A multi-scale 3D model of the vacuum arc remelting process

Corrigendum to ??Influence of processing conditions on strut structure and compressive properties of cellular lattice structures fabricated by selective laser melting?? [Mater. Sci. Eng. A 628(2015)188?197]