Additive manufacturing of metallic components – Process, structure and properties

This article presents an overview of the developments in stainless steels made since the 1990s. Some of the new applications that involve the use of stainless steel are also introduced. A brief introduction to the various classes of stainless steels, their precipitate phases and the status quo of their production around the globe is given first. The advances in a variety of subject areas that have been made recently will then be presented. These recent advances include (1) new findings on the various precipitate phases (the new J phase, new orientation relationships, new phase diagram for the Fe–Cr system, etc.); (2) new suggestions for the prevention/mitigation of the different problems and new methods for their detection/measurement and (3) new techniques for surface/bulk property enhancement (such as laser shot peening, grain boundary engineering and grain refinement). Recent developments in topics like phase prediction, stacking fault energy, superplasticity, metadynamic recrystallisation and the calculation of mechanical properties are introduced, too. In the end of this article, several new applications that involve the use of stainless steels are presented. Some of these are the use of austenitic stainless steels for signature authentication (magnetic recording), the utilisation of the cryogenic magnetic transition of the sigma phase for hot spot detection (the Sigmaplugs), the new Pt-enhanced radiopaque stainless steel (PERSS) coronary stents and stainless steel stents that may be used for magnetic drug targeting. Besides recent developments in conventional stainless steels, those in the high-nitrogen, low-Ni (or Ni-free) varieties are also introduced. These recent developments include new methods for attaining very high nitrogen contents, new guidelines for alloy design, the merits/demerits associated with high nitrogen contents, etc.

Recent developments in stainless steels

In the laser treatment of a workpiece (9), e.g. for surface hardening, melting, alloying, cladding, welding or cutting, the adverse effect of reflectivity of the surface, when a pure, monochromatic laser (6) is used, is remedied by the simultaneous application of a relatively shorter wavelength beam (1). The two beams (1)(5) may be combined by a beam coupler (4) or may reach the workpiece (9) by separate optical paths (not shown). The shorter wavelength beam (1) improves the coupling efficiency of the higher- powered laser beam (5).

Laser Material Processing

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing

Laser shock processing and its effects on microstructure and properties of metal alloys: a review

Subjecting target metallic samples to a very short pulse (about 20 ns) of intense (GW cm−2) laser light generates, through a surface plasma, a high-pressure stress wave propagating to the first millimetre in depth, which is commonly called laser shock processing (LSP). The purpose of this work was to evaluate the role of this novel process on the cyclic properties of A356, Al12Si and 7075 aluminium alloys. Major contributors to the fatigue performance improvements were investigated in order to determine the optimum shock conditions. These were mainly compressive residual stress (RS) levels for which a large range of incident shock conditions was performed. We showed that stress levels were very sensitive to the laser fluence and the number of local impacts, and experimental RS measurements were found to be in good agreement with analytical modelling results. In comparison, a conventional shot peening (SP) treatment was found to lead to higher surface hardening and RS levels, but with a very detrimental roughening not observed after LSP. High cycle (107) fatigue tests carried out on laser- processed, shot-peened and untreated notched samples illustrated the efficiency of LSP as a new, promising method to improve the fatigue limits σD of structures, especially in comparison with enhancements displayed by SP (+22% vs. +10%). According to crack detection electric measurements, fatigue performance improvements with LSP mainly occurred during the crack initiation stage.

Laser shock processing of aluminium alloys. Application to high cycle fatigue behaviour

Generation of a high amplitude shock wave by laser plasma in a water confinement regime has been investigated for an incident 25–30 ns/40 J/λ=1.064 μm pulsed laser beam. Experimental measurements of temporal and spatial profiles of induced shock waves for this regime of laser shock processing of materials were performed using a velocimetry interferometer system for any reflector system. Above a 10 GW/cm2 laser intensity threshold, a saturation of the peak pressure is shown to occur while the pressure pulse duration is reduced by parasitic plasma occurring in the confining water. The observation of the interaction zone with a fast camera system shows that this breakdown plasma, which mainly occurs at the very surface of the water rather than within the water volume, limits the efficiency of the process. This plasma absorbs the incident laser energy, and the power density reaching the target gradually decreases with increasing power densities while the shock-wave duration is correspondingly reduced. Both pr...

Shock waves from a water-confined laser-generated plasma

The first part of this article presents a review of the main process parameters controlling pressure generation in a confined mode The effect of laser intensity, target material, laser pulse duration, and laser wavelength are, therefore, discussed An optimized process can then be defined The second part of this article deals with the surface modifications induced by laser-shock processing The generation of residual compressive stresses is then highlighted Finally, in the third part, the interest of laser-shock processing is discussed for several typical applications A conclusion will present the future trends of this technique

Physics and applications of laser-shock processing

The influence of laser peening (LP) on the electrochemical behavior of AISI type 316L stainless steel in a saline environment was evaluated. Surface modifications were investigated as they might have beneficial effects on the corrosion behaviour. Low residual stress and work hardening levels were found, when compared with a conventional shot-peening (SP) treatment, mainly because of the absence of martensite transformation in the case of LP. Surface changes were accompanied by small roughening effects and a global preservation of the surface chemistry after treatment. Therefore, electrochemical tests performed on samples after LP and SP treatments showed increases in rest potentials, reductions of passive current densities and anodic shifts of the pitting potentials evidenced by a stochastic approach of pitting. The better pitting resistance was observed after LP treatment, which seems to reflect a reduction or an elimination of active sites for pitting at lower potentials. Even though the deleterious surface state of shot peened surfaces possibly counterbalances the beneficial influence of residual stresses, a beneficial influence of mechanical surface treatments has been demonstrated regarding the localized corrosion properties.

Surface modifications induced in 316L steel by laser peening and shot-peening. Influence on pitting corrosion resistance

The direct metal deposition (DMD) laser process is a novel technique, well adapted for aeronautical applications, that allows the building of complex 3D geometries through the interaction between a powder nozzle system and a continuous laser beam. A three-step analytical and numerical approach was carried out to predict the shapes of manufactured structures and thermal loadings induced by the DMD process. First, powder temperature was calculated using a recent analytical model, then the geometry of walls was predicted by a combined numerical + analytical modelling using a discretization of the physical interaction domain, and finally, a finite element calculation was carried out on COMSOL 3.3 Multiphysics software to describe thermal behaviour during DMD of a titanium alloy.Our thermal model takes into account the moving interface during metal deposition with a specific function κ (t, x, y, z) allowing the conductivity front to move simultaneously with the moving laser source (with an appropriate spatial energy distribution), thus representing rather precisely the DMD process. This allowed us to provide an adequate representation of temperatures near the melt-pool, and to reproduce with a good accuracy thermal cycles and melt-pool dimensions during the construction of up to 25-layer walls. This was confirmed by comparisons with experimental thermocouple data T = f(t), and fast camera melt-pool recording.

https://iopscience.iop.org/article/10.1088/0022-3727/41/2/025403/pdf

Rémy Fabbro

Papers

Laser shock processing of aluminium alloys. Application to high cycle fatigue behaviour

Shock waves from a water-confined laser-generated plasma

Physics and applications of laser-shock processing

Surface modifications induced in 316L steel by laser peening and shot-peening. Influence on pitting corrosion resistance

Analytical and numerical modelling of the direct metal deposition laser process