Additively manufactured materials and structures: A state-of-the-art review on their mechanical characteristics and energy absorption

Microstructural evolution and mechanical properties of Inconel 625 superalloy fabricated by pulsed microplasma rapid additive manufacturing

Selective Laser Melting (SLM) process has a great potential to create unique 3D components of AlSi10Mg with exceptional degrees of freedom for wide range of applications in industries. However, the presence of porosity and other defects influenced by process parameters can be harmful to fabricated components in some applications. Process parameters and post-processing treatments helps in minimizing the metallurgical defects and enhance the mechanical properties. This review aims to provide a detailed description of the recent research done on the SLM-AlSi10Mg including the effect of SLM process parameters on the mechanical properties of the alloy. The effect of different heat treatments on the microstructure and overall mechanical properties of SLM fabricated AlSi10Mg alloy parts also discussed. The findings of the review revealed that the density of additively manufactured AlSi10Mg built part first increases with increase in energy density and then decreases above threshold value due to lack of fusion at low energy and at high energy key hole formation take place. Tensile strength of the built parts is affected by the process parameters, built direction, baseplate preheating temperature and built environment. The process parameters and built condition also affect the roughness and hardness of additively manufactured AlSi10Mg parts. Heat and surface treatment also help to improve the mechanical and surface properties by changing microstructure orientation. Furthermore, a comprehensive study of various surface finishing techniques based on energy sources such as mechanical, chemical and thermal improves the surface roughness and fatigue life of SLM fabricated AlSi10Mg parts is also presented. 

A comprehensive review on the effect of process parameters and post-process treatments on microstructure and mechanical properties of selective laser melting of AlSi10Mg

Direct metal printing is a promising technique for manufacturing injection molds with complex conformal cooling channels from maraging steel powder, which is widely applied in automotive or aerospace industries. However, two major disadvantages of direct metal printing are the narrow process window and length of time consumed. The fabrication of high-density injection molds is frequently applied to prevent coolant leakage during the cooling stage. In this study, we propose a simple method of reducing coolant leakage for a direct-metal-printed injection mold with conformal cooling channels by combining injection mold fabrication with general process parameters, as well as solution and aging treatment (SAT). This study comprehensively investigates the microstructural evolution of the injection mold after SAT using field-emission scanning electron microscopy and energy-dispersive X-ray spectroscopy. We found that the surface hardness of the injection mold was enhanced from HV 189 to HV 546 as the Ni-Mo precipitates increased from 12.8 to 18.5%. The size of the pores was reduced significantly due to iron oxide precipitates because the relative density of the injection mold increased from 99.18 to 99.72%. The total production time of the wax injection mold without coolant leakage during the cooling stage was only 62% that of the production time of the wax injection mold fabricated with high-density process parameters. A significant savings of up to 46% of the production cost of the injection mold was obtained.

A Simple Method of Reducing Coolant Leakage for Direct Metal Printed Injection Mold with Conformal Cooling Channels Using General Process Parameters and Heat Treatment

Effect of individual printing parameters on residual stress and tribological behaviour of 316L stainless steel fabricated with laser powder bed fusion (L-PBF)

Wire arc additive manufacturing (WAAM) has attracted more attention in recent years, due to its ability to create large components with high material deposition rate and low cost of equipment. It is getting more popular nowadays because it provides high strength at low cost, high deposition rate, faster build time, and optimum heat input. In this article, a comprehensive literature review has been covered to show the effect of different process parameters on mechanical and microstructural properties. Primarily, aim is to provide information about accuracy of WAAM manufactured part in correlation with change in different processes parameters such as heat input, current, voltage, wire feed rate, and travel speed. This paper also gives an idea about which parameters can be used to get desired mechanical and microstructural properties. It also provides information about challenges that lead to abnormal results and remedies to overcome with heterogeneous and anisotropic properties of materials. Selection of process parameters help to optimize the WAAM process to obtain the desired geometry with required properties.

A Review on Wire Arc Additive Manufacturing: Effect of Process Parameters on the Build Material Properties

Effect of deposition strategies on mechanical strength of wire arc additively manufactured Inconel 625

AbstractThis study presents the impact of friction stir processing (FSP) on the surface characteristics such as hardness and wear of aluminum alloys. Aluminum alloys (Al) have the potential to be applied in various engineering applications. However, it does not have the required surface properties. Researchers have been working on improving the material properties of Al alloys for the past many years. FSP has gained attention in the last decade because of its ability to modify the material’s characteristics. In the recent times, FSP has gained interest among the researchers. FSP results in an intense plastic deformation and amalgamation of materials which result in a refined and uniform microstructure, leading to better hardness values and improved wear resistance. Moreover, defects like porosity, voids, thermal cracks could be minimized in the stir zone at optimal tool parameters. This study reviews the influence of various process parameters like tool geometry, tool rotational speed, number of passes, processing regions, reinforcement particles, and volume percentage of these particles on Al alloys.KeywordsFriction stir processingAluminum alloysReinforcement particlesHardnessWear 

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Papers

A Review on Wire Arc Additive Manufacturing: Effect of Process Parameters on the Build Material Properties

Effect of deposition strategies on mechanical strength of wire arc additively manufactured Inconel 625

A Review on Improving the Surface Characteristics of Aluminum Alloy via Friction Stir Processing