There is, I think, something ethereal about i —the square root of minus one. I remember first hearing about it at school. It seemed an odd beast at that time—an intruder hovering on the edge of reality.

Usually familiarity dulls this sense of the bizarre, but in the case of i it was the reverse: over the years the sense of its surreal nature intensified. It seemed that it was impossible to write mathematics that described the real world in …

I and i

Additive manufacturing of metallic components – Process, structure and properties

Additive manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire or sheets in a process that proceeds layer by layer. Many techniques (using many different names) have been developed to accomplish this via melting or solid-state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid-state precipitation, mechanical properties and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Only a few alloys have been developed for commercial production, but recent efforts are presented as a path for the ongoing development of new materials for AM processes.

The metallurgy and processing science of metal additive manufacturing

Modelling of inoculation of metallic melts : Application to grain refinement of aluminium by Al-Ti-B

A new approach to the modelling of grain structure formation in solidification processes is proposed. Based upon a two-dimensional cellular automata technique, the model includes the mechanisms of heterogeneous nucleation and of grain growth. Nucleation occurring at the mould wall as well as in the liquid metal are treated by using two distributions of nucleation sites. The location and the crystallographic orientation of the grains are chosen randomly among a large number of cells and a certain number of orientation classes, respectively. The growth kinetics of the dendrite tip and the preferential 〈100〉 growth directions of cubic metals are taken into account. The model is then applied to small specimens of uniform temperature. The columnar-to-equiaxed transition, the selection and extension of columnar grains which occur in the columnar zone and the impingement of equiaxed grains are clearly shown by this technique. The calculated effect of the alloy concentration and cooling rate upon the resultant microstructure agree with experimental observations.

Probabilistic modelling of microstructure formation in solidification processes

Additive manufacturing by selective laser melting (SLM) was used to investigate the effect of laser energy density on 316L stainless steel properties. Point distance and exposure time were varied and their impact on porosity, surface finish, microstructure, density and hardness, was evaluated. The surface roughness was primarily affected by point distance with increased point distance resulting in increased surface roughness, R
 a, from 10 to 16 μm. Material hardness reached a maximum of 225 HV at 125 J/mm3 and was related to the material porosity; with increased porosity leading to decreased material hardness. Different types of particle coalescence leading to convex surface features were observed (sometimes referred to as balling); from small ball features at low laser energy density to a mixture of both small and large ball features at high laser energy density. Laser energy density was shown to affect total porosity. The minimum amount of porosity, 0.38 %, was observed at an energy density of 104.52 J/mm3.

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Investigation into the effect of process parameters on microstructural and physical properties of 316L stainless steel parts by selective laser melting

Computer simulation of the effects of alloy variables on the grain structures of castings

Powder Bed Additive Manufacturing offers unique advantages in terms of manufacturing cost, lot size, and product complexity compared to traditional processes such as casting, where a minimum lot size is mandatory to achieve economic competitiveness. Many studies—both experimental and numerical—are dedicated to the analysis of how process parameters such as heat source power, scan speed, and scan strategy affect the final material properties. Apart from the general urge to increase the build rate using thicker powder layers, the coating process and how the powder is distributed on the processing table has received very little attention to date. This paper focuses on the first step of every powder bed build process: Coating the process table. A numerical study is performed to investigate how powder is transferred from the source to the processing table. A solid coating blade is modeled to spread commercial Ti-6Al-4V powder. The resulting powder layer is analyzed statistically to determine the packing density and its variation across the processing table. The results are compared with literature reports using the so-called “rain” models. A parameter study is performed to identify the influence of process table displacement and wiper velocity on the powder distribution. The achieved packing density and how that affects subsequent heat source interaction with the powder bed is also investigated numerically.

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Powder Bed Layer Characteristics: The Overseen First-Order Process Input

The microstructure and mechanical properties of 316L steel have been examined for parts built by a powder bed laser fusion process, which uses a laser to melt and build parts additively on a layer by layer basis. Relative density and porosity determined using various experimental techniques were correlated against laser energy density. Based on porosity sizes, morphology and distributions, the porosity was seen to transition between an irregular, highly directional porosity at the low laser energy density and a smaller, more rounded and randomly distributed porosity at higher laser energy density, thought to be caused by keyhole melting. In both cases, the porosity was reduced by hot isostatic pressing (HIP). High throughput ultrasound based measurements were used to calculate elasticity properties and show that the lower porosities from builds with higher energy densities have higher elasticity moduli in accordance with empirical relationships, and hot isostatic pressing improves the elasticity properties to levels associated with wrought/rolled 316L. However, even with hot isostatic pressing the best properties were obtained from samples with the lowest porosity in the as-built condition. A finite element stress analysis based on the porosity microstructures was undertaken, to understand the effect of pore size distributions and morphology on the Young's modulus. Over 1–5% porosity range angular porosity was found to reduce the Young's modulus by 5% more than rounded porosity. Experimentally measured Young's moduli for samples treated by HIP were closer to the rounded trends than the as-built samples, which were closer to angular trends. Tensile tests on specimens produced at optimised machine parameters displayed a high degree of anisotropy in the build direction and test variability for as-built parts, especially between vertical and horizontal build directions. The as-built properties were generally found to have a higher yield stress, but lower upper tensile strength and elongation than published data for wrought/hot-rolled plate 316L. The hot isostatically pressed parts showed a homogenisation of the properties across build directions and properties much more akin to those of wrought/hot-rolled 316L, with an increase in elongation and upper tensile strength, and a reduction in yield over the as-built samples.

/pdf/effects-of-hot-isostatic-pressing-on-the-elastic-modulus-and-2e0k5oujoa.pdf

Effects of hot isostatic pressing on the elastic modulus and tensile properties of 316L parts made by powder bed laser fusion

Despite its excellent elemental properties, lightweight nature and good alloying potential, scandium has received relatively little attention in the manufacturing community. The abundance of scandium in the Earth's crust is quite high. It is more abundant than silver, cobalt, lead and tin. But, because scandium is so well dispersed in the lithosphere, it is notoriously difficult to extract in commercial quantities – hence low market availability and high cost. Scandium metallurgy is still a largely unexplored field – but progress is being made. This review aims to summarise advances in scandium metallurgical research over the last decade. The use of scandium as a conventional minor addition to alloys, largely in structural applications, is described. Also, more futuristic functional applications are discussed where details of crystal structures and peculiar symmetries are often of major importance. This review also includes data obtained from more obscure sources (especially Russian publications) which ar...

/pdf/the-scandium-effect-in-multicomponent-alloys-ucppmxo9qg.pdf

S. G. R. Brown

Papers

Investigation into the effect of process parameters on microstructural and physical properties of 316L stainless steel parts by selective laser melting

Computer simulation of the effects of alloy variables on the grain structures of castings

Powder Bed Layer Characteristics: The Overseen First-Order Process Input

Effects of hot isostatic pressing on the elastic modulus and tensile properties of 316L parts made by powder bed laser fusion

The scandium effect in multicomponent alloys