High entropy alloys: A focused review of mechanical properties and deformation mechanisms

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

Friction stir welding/processing of metals and alloys: A comprehensive review on microstructural evolution

BACKGROUNDMetallic components are the cornerstone of modern industries such as aviation, aerospace, automobile manufacturing, and energy production. The stringent requirements for high-performance metallic components impede the optimization of materials selection and manufacturing. Laser-based additive manufacturing (AM) is a key strategic technology for technological innovation and industrial sustainability. As the number of applications increases, so do the scientific and technological challenges. Because laser AM has domain-by-domain (e.g., point-by-point, line-by-line, and layer-by-layer) localized forming characteristics, the requisite for printing process and performance control encompasses more than six orders of magnitude, from the microstructure (nanometer- to micrometer-scale) to macroscale structure and performance of components (millimeter- to meter-scale). The traditional route of laser-metal AM follows a typical “series mode” from design to build, resulting in a cumbersome trial-and-error methodology that creates challenges for obtaining high-performance goals.ADVANCESWe propose a holistic concept of material-structure-performance integrated additive manufacturing (MSPI-AM) to cope with the extensive challenges of AM. We define MSPI-AM as a one-step AM production of an integral metallic component by integrating multimaterial layout and innovative structures, with an aim to proactively achieve the designed high performance and multifunctionality. Driven by the performance or function to be realized, the MSPI-AM methodology enables the design of multiple materials, new structures, and corresponding printing processes in parallel and emphasizes their mutual compatibility, providing a systematic solution to the existing challenges for laser-metal AM. MSPI-AM is defined by two methodological ideas: “the right materials printed in the right positions” and “unique structures printed for unique functions.” The increasingly creative methods for engineering both micro- and macrostructures within single printed components have led to the use of AM to produce more complicated structures with multimaterials. It is now feasible to design and print multimaterial components with spatially varying microstructures and properties (e.g., nanocomposites, in situ composites, and gradient materials), further enabling the integration of functional structures with electronics within the volume of a laser-printed monolithic part. These complicated structures (e.g., integral topology optimization structures, biomimetic structures learned from nature, and multiscale hierarchical lattice or cellular structures) have led to breakthroughs in both mechanical performance and physical/chemical functionality. Proactive realization of high performance and multifunctionality requires cross-scale coordination mechanisms (i.e., from the nano/microscale to the macroscale).OUTLOOKOur MSPI-AM continues to develop into a practical methodology that contributes to the high performance and multifunctionality goals of AM. Many opportunities exist to enhance MSPI-AM. MSPI-AM relies on a more digitized material and structure development and printing, which could be accomplished by considering different paradigms for AM materials discovery with the Materials Genome Initiative, standardization of formats for digitizing materials and structures to accelerate data aggregation, and a systematic printability database to enhance autonomous decision-making of printers. MSPI-oriented AM becomes more intelligent in processes and production, with the integration of intelligent detection, sensing and monitoring, big-data statistics and analytics, machine learning, and digital twins. MSPI-AM further calls for more hybrid approaches to yield the final high-performance/multifunctional achievements, with more versatile materials selection and more comprehensive integration of virtual manufacturing and real production to navigate more complex printing. We hope that MSPI-AM can become a key strategy for the sustainable development of AM technologies. Download high-res image Open in new tab Download PowerpointMaterial-structure-performance integrated additive manufacturing (MSPI-AM).Versatile designed materials and innovative structures are simultaneously printed within an integral metallic component to yield high performance and multifunctionality, integrating in parallel the core elements of material, structure, process, and performance and a large number of related coupling elements and future potential elements to enhance the multifunctionality of printed components and the maturity and sustainability of laser AM technologies.

Material-structure-performance integrated laser-metal additive manufacturing.

Selective laser melting of an equiatomic CoCrFeMnNi high-entropy alloy: Processability, non-equilibrium microstructure and mechanical property

Developing a high-strength Al-Mg-Si-Sc-Zr alloy for selective laser melting: Crack-inhibiting and multiple strengthening mechanisms

Selective laser melting of a novel Sc and Zr modified Al-6.2 Mg alloy: Processing, microstructure, and properties

Effect of aging treatment on the microstructure and mechanical properties of Al-3.02Mg-0.2Sc-0.1Zr alloy printed by selective laser melting

Anisotropic mechanical behavior of biomedical Ti-13Nb-13Zr alloy manufactured by selective laser melting

As the typical refractory metal, the W-Ni-Cu alloy faces severe challenge in machining of complex shapes. To deal with the problem, we use selective laser melting (SLM) additive manufacturing to consolidate W-10%Ni-10%Cu composite powder. The effects of laser parameters on densification, microstructural evolution and nano-crystalline formation were studied. With the increase of laser energy density, the absolute density increases apparently and the surface unevenness is slightly alleviated. Except the typical W and Ni-Cu solid solution phases, interestingly, the amorphous W-Ni solid solution was detected in the SLM processed sample. The typical microstructure contains un-melted W region, W dendrite region with the melting of W and Ni-Cu region. The W solidification microstructure adjacent to the un-melt W presents cellular grain and then transforms into columnar dendrite, until it finally becomes equiaxed dendrite. A large number of W-based nanocrystals formed during the solidification process, which was caused by Marangoni migration that the Ni-Cu phase tends to break the liquid W into small ones, yielding the formation nano-crystalline. Better understanding of the corresponding metallurgical mechanisms will help pave the way towards newly refractory metal design for additive manufacturing application.

Selective laser melting of W-Ni-Cu composite powder: Densification, microstructure evolution and nano-crystalline formation

Minbo Wang

Papers

Developing a high-strength Al-Mg-Si-Sc-Zr alloy for selective laser melting: Crack-inhibiting and multiple strengthening mechanisms

Selective laser melting of a novel Sc and Zr modified Al-6.2 Mg alloy: Processing, microstructure, and properties

Effect of aging treatment on the microstructure and mechanical properties of Al-3.02Mg-0.2Sc-0.1Zr alloy printed by selective laser melting

Anisotropic mechanical behavior of biomedical Ti-13Nb-13Zr alloy manufactured by selective laser melting

Selective laser melting of W-Ni-Cu composite powder: Densification, microstructure evolution and nano-crystalline formation