This paper reviews the state-of-the-art of an important, rapidly emerging, manufacturing technology that is alternatively called additive manufacturing (AM), direct digital manufacturing, free form fabrication, or 3D printing, etc. A broad contextual overview of metallic AM is provided. AM has the potential to revolutionize the global parts manufacturing and logistics landscape. It enables distributed manufacturing and the productions of parts-on-demand while offering the potential to reduce cost, energy consumption, and carbon footprint. This paper explores the material science, processes, and business consideration associated with achieving these performance gains. It is concluded that a paradigm shift is required in order to fully exploit AM potential.

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Metal Additive Manufacturing: A Review

Additive manufacturing of metals

This article reviews published data on the mechanical properties of additively manufactured metallic materials. The additive manufacturing techniques utilized to generate samples covered in this review include powder bed fusion (e.g., EBM, SLM, DMLS) and directed energy deposition (e.g., LENS, EBF3). Although only a limited number of metallic alloy systems are currently available for additive manufacturing (e.g., Ti-6Al-4V, TiAl, stainless steel, Inconel 625/718, and Al-Si-10Mg), the bulk of the published mechanical properties information has been generated on Ti-6Al-4V. However, summary tables for published mechanical properties and/or key figures are included for each of the alloys listed above, grouped by the additive technique used to generate the data. Published values for mechanical properties obtained from hardness, tension/compression, fracture toughness, fatigue crack growth, and high cycle fatigue are included for as-built, heat-treated, and/or HIP conditions, when available. The effects of test...

Metal Additive Manufacturing: A Review of Mechanical Properties

Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing

https://cmapspublic3.ihmc.us/rid=1P89G039W-1JGLLQJ-17GJ/DED%20Properties.pdf

Anisotropic tensile behavior of Ti-6Al-4V components fabricated with directed energy deposition additive manufacturing

The macro and microstructure of laser-deposited Ti-6Al-4V has been investigated to determine the evolution of unique microstructural features in mutilayer builds. The macro and microstructures exhibited in the build include large, columnar prior-beta grains, a gradient in the individual alpha-lath thickness between the deposited layers, and the presence of layer bands within each layer, except for the last three layers deposited. The layer band consists of a colony Widmanstatten alpha morphology, while the nominal microstructure between layer bands exhibits a basketweave morphology. Optical microscopy, hardness, and composition measurements were used to determine that the layer-band and gradient morphologies are resultant from the complex thermal history the build experiences and not a result of segregation or oxidation. The gradient alpha and layer-band morphologies form in layer n after the deposition of layer n+3.

Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part I. Microstructural characterization

The thermal history developed in laser metal deposition (LMD) processes has been shown to be quite complex and results in the evolution of an equally complex microstructure. A companion article (Part I. Microstructural Characterization) discussed the LMD of Ti-6Al-4V, where the resultant microstructure consists of a periodic, scale-graded layer of basketweave Widmanstatten alpha and a banding that consists of colony Widmanstatten alpha. In order to understand the microstructural evolution in Ti-6Al-4V, a numerical thermal model based on the implicit finite-difference technique was developed to model LMD processes. The effect of different laser-scan velocities on the characteristics of the thermal history was investigated using an eight-layer single-line build. As the laser-scan speed decreases and the position within a layer increases, the peak temperature increases. The heating rate and the peak thermal gradient within a deposited layer were shown to follow the same trend as the peak temperature after two layers were deposited on top of the substrate. In general, the laser-scan speed or z-position within a layer did not have a significant effect on the cooling rate. The cooling rate in a newly deposited layer decreases as the number of layer additions increases. Given the predicted temperature vs time profile from the thermal model, the evolution of phase transformations occurring in the deposit is mapped as each layer is deposited. As a result of the thermal cycling imposed by the periodic deposition of material, a characteristic layer, consisting of two regions heated above and below the beta transus, forms in layer n due to the deposition of layer n+1.

Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part II. Thermal modeling

The performance of fiber-reinforced composites is often controlled by the properties of the fiber–matrix interface. Good interfacial bonding (or adhesion), to ensure load transfer from matrix to reinforcement, is a primary requirement for effective use of reinforcement properties. Thus, a fundamental understanding of interfacial properties and a quantitative characterization of interfacial adhesion strength can help in evaluating the mechanical behavior and capabilities of composite materials. A large number of analytical techniques have been developed for understanding interfacial adhesion of glass-fiber-reinforced polymers. Among these techniques, the vibration damping technique has the advantage of being non-destructive as well as highly sensitive for evaluating the interfacial region, and it can allow the materials industry to rapidly determine the mechanical properties of composites. In the present study, a simple optical system was contributed for measuring the damping factor of uniaxial fiber-reinforced polymer composites in the shape of cantilever beams. The interfacial damping factors in glass-fiber-reinforced epoxy resin composites were correlated with transverse tensile strength, which is a qualitative measurement of adhesion at the fiber–matrix interface. Four different composite systems were tested in this study. In each system, three different surface treatments of glass-fiber at three different volume fractions were evaluated. The experimental results show an inverse relationship between damping contributed by the interface and composite transverse tensile strength.

Volume fraction effects on interfacial adhesion strength of glass-fiber-reinforced polymer composites

A series of TiB2-reinforced near-γ titanium aluminide (Ti-Al) matrix composites have been produced in investment-cast form and characterized with respect to microstructure and tensile deformation. The Ti-Al matrices of the composites examined are based upon the binary composition Ti-47 Al (at. pct), with varying proportions (2 to 6 cumulative percent) of manganese, vanadium, chromium, and niobium. TiB2 has been introduced into the microstructuresvia XD* processing at levels of 7 and 12 vol pct and compared to unreinforced (0 vol pct TiB2), base variants. The influences of heat-treatment temperature and time have also been studied for each composition and reinforcement variant. The addition of dispersed TiB2 leads to a fine, stable, and homogeneous as-cast matrix microstructure. The measured TiB2 size within the composites examined ranged from 1.4 to 2.6 µm. Increasing the volume fraction of TiB2 leads to increased elastic moduli, increased ambient temperature tensile strengths, and in general, increased strain-hardening response. In some instances, the overall ductility of the alloy increases with the addition of TiB2 reinforcement. The flow stresses of both the monolithic and composite variants exhibit conventional power-law plasticity. The results indicate that the strengthening and the flow behavior in these composites are derived from both indirect and direct sources. Strengthening contributions are indirectly derived from the microstructural changes within the matrix of the composite that evolve due to the presence of the reinforcement during its evolution and development, for example, due to grain refinement and reinforcement-derived interstitial solid-solution strengthening. Direct contributions to strength are those that can be specifically attributed to the presence of the reinforcement during deformation,e.g., through the interaction of dislocations with the reinforcing particles. When the estimates of the indirect contributions are isolated and arithmetically removed from the magnitude of the total observed strength of the composite, the increase in flow stress correlates in all instances with the inverse square root of the planar interparticle spacing for all alloy compositions, heat treatments, and levels of strain examined.

Room-Temperature strength and deformation of Tib2-reinforced near-γ titanium aluminides

Composite materials are disclosed comprising a continuous matrix with composite reinforcements therein. The composite materials may include a continuous metal, metal alloy or intermetallic matrix with intermetallic matrix composite reinforcements dispersed therein. Suitable metals for the continuous matrix include Al, Ti, Cu and Fe, and alloys and intermetallics thereof. The composite reinforcements comprise ceramic particles dispersed in a continuous intermetallic matrix. Suitable intermetallics include alumnides of Ti, Cu, Ni, Mg and Fe, while suitable ceramics include refractory metal borides, carbides, nitrides, sulicides and sulfides. In one embodiment, the ceramic particles are formed in-situ within the intermetallic matrix of the composite reinforcements. The composite materials are produced by powder metallurgical techniques wherein powders of the continuous matrix component and powders of the composite reinforcement are blended and consolidated. The composite materials may be subjected to deformation processes such as extruding, rolling and forging during or after the consolidation step to provide materials with improved properties.

Stephen L. Kampe

Papers

Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part I. Microstructural characterization

Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part II. Thermal modeling

Volume fraction effects on interfacial adhesion strength of glass-fiber-reinforced polymer composites

Room-Temperature strength and deformation of Tib2-reinforced near-γ titanium aluminides

Method of producing composite materials including metallic matrix composite reinforcements