Additive manufacturing of metals

doi:10.1016/J.ACTAMAT.2016.07.019

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Additive manufacturing of metals

Journal Article•DOI•

Additive manufacturing of metals

Dirk Herzog¹, Vanessa Seyda, Eric Wycisk, Claus Emmelmann¹•Institutions (1)

Hamburg University of Technology¹

15 Sep 2016-Acta Materialia (Pergamon)-Vol. 117, Iss: 117, pp 371-392

TL;DR: In this paper, the authors describe the complex relationship between additive manufacturing processes, microstructure and resulting properties for metals, and typical microstructures for additively manufactured steel, aluminium and titanium are presented.

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About: This article is published in Acta Materialia.The article was published on 2016-09-15. It has received 2837 citations till now. The article focuses on the topics: Aluminium.

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Journal Article•DOI•

Additive manufacturing of metallic components – Process, structure and properties

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Tarasankar Debroy¹, Huiliang Wei¹, J.S. Zuback¹, T. Mukherjee¹, John W. Elmer², John O. Milewski, Allison M. Beese¹, Alexander E. Wilson-Heid¹, Amitava De³, Wei Zhang⁴ - Show less +6 more•Institutions (4)

Pennsylvania State University¹, Lawrence Livermore National Laboratory², Indian Institute of Technology Bombay³, Ohio State University⁴

01 Mar 2018-Progress in Materials Science

TL;DR: A review of the emerging research on additive manufacturing of metallic materials is provided in this article, which provides a comprehensive overview of the physical processes and the underlying science of metallurgical structure and properties of the deposited parts.

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4,192 citations

Cites background from "Additive manufacturing of metals"

...Nearly all of the heat treatable aluminum alloys are welded using dissimilar filler metals near the Al-Si eutectic, and these alloys have proven to be popular alloys for AM processing [4,310,384,387,440,441]....
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...The metallurgy of all of these alloys can be complex, and subject to individual AM processing parameters as well as the final heat treating conditions [2,4,444], which can sometimes be incorporated into a hot isostatic press (HIP) treatment to remove residual stress and minimize porosity at the same time [2]....
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...Another reason is that, in order to achieve uniform and high strength properties, the AM builds must undergo post build heat treating (PHT) to achieve the desired properties [2,4]....
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...Austenitic stainless steels, AISI 304L and 316L, are very important engineering alloys that are readily weldable if the compositions are controlled to prevent solidification cracking [210,293] and have been a popular AM material [4,312,357,380]....
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...The most common aluminum alloys processed by AM are the eutectic Al-Si and the hardenable Al-Si-Mg alloys [4]....
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Journal Article•DOI•

Additive manufacturing (3D printing): A review of materials, methods, applications and challenges

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Tuan Ngo¹, Alireza Kashani¹, Gabriele Imbalzano¹, Kate Nguyen¹, David Hui² - Show less +1 more•Institutions (2)

University of Melbourne¹, University of New Orleans²

15 Jun 2018-Composites Part B-engineering

TL;DR: A comprehensive review of the main 3D printing methods, materials and their development in trending applications was carried out in this paper, where the revolutionary applications of AM in biomedical, aerospace, buildings and protective structures were discussed.

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Abstract: Freedom of design, mass customisation, waste minimisation and the ability to manufacture complex structures, as well as fast prototyping, are the main benefits of additive manufacturing (AM) or 3D printing. A comprehensive review of the main 3D printing methods, materials and their development in trending applications was carried out. In particular, the revolutionary applications of AM in biomedical, aerospace, buildings and protective structures were discussed. The current state of materials development, including metal alloys, polymer composites, ceramics and concrete, was presented. In addition, this paper discussed the main processing challenges with void formation, anisotropic behaviour, the limitation of computer design and layer-by-layer appearance. Overall, this paper gives an overview of 3D printing, including a survey on its benefits and drawbacks as a benchmark for future research and development.

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4,159 citations

Journal Article•DOI•

Additively manufactured hierarchical stainless steels with high strength and ductility

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Y. Morris Wang¹, Thomas Voisin¹, Joseph T. McKeown¹, Jianchao Ye¹, Nicholas P. Calta¹, Zan Li¹, Zhi Zeng², Yin Zhang², Wen Chen¹, Tien T. Roehling¹, Ryan T. Ott³, Melissa K. Santala⁴, Philip J. Depond¹, Manyalibo J. Matthews¹, Alex V. Hamza¹, Ting Zhu² - Show less +12 more•Institutions (4)

Lawrence Livermore National Laboratory¹, Georgia Institute of Technology², Ames Laboratory³, Oregon State University⁴

01 Jan 2018-Nature Materials

TL;DR: The potential of additive manufacturing to create alloys with unique microstructures and high performance for structural applications is demonstrated, with austenitic 316L stainless steels additively manufactured via a laser powder-bed-fusion technique exhibiting a combination of yield strength and tensile ductility that surpasses that of conventional 316L steels.

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Abstract: Many traditional approaches for strengthening steels typically come at the expense of useful ductility, a dilemma known as strength-ductility trade-off. New metallurgical processing might offer the possibility of overcoming this. Here we report that austenitic 316L stainless steels additively manufactured via a laser powder-bed-fusion technique exhibit a combination of yield strength and tensile ductility that surpasses that of conventional 316L steels. High strength is attributed to solidification-enabled cellular structures, low-angle grain boundaries, and dislocations formed during manufacturing, while high uniform elongation correlates to a steady and progressive work-hardening mechanism regulated by a hierarchically heterogeneous microstructure, with length scales spanning nearly six orders of magnitude. In addition, solute segregation along cellular walls and low-angle grain boundaries can enhance dislocation pinning and promote twinning. This work demonstrates the potential of additive manufacturing to create alloys with unique microstructures and high performance for structural applications.

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1,385 citations

Journal Article•DOI•

Additive manufacturing of Ti6Al4V alloy: A review

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Shunyu Liu¹, Yung C. Shin¹•Institutions (1)

Purdue University¹

15 Feb 2019-Materials & Design

TL;DR: In this paper, the recent progress on Ti6Al4V fabricated by three mostly developed additive manufacturing techniques-directed energy deposition (DED), selective laser melting (SLM) and electron beam melting (EBM)-is thoroughly investigated and compared.

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1,248 citations

Cites methods from "Additive manufacturing of metals"

...With respect to the fabrication of dense metallic structures, powder-based AM techniques such as DED, SLM and EBM are mostly used [22,23,26]....
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Journal Article•DOI•

A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement

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Bintao Wu¹, Zengxi Stephen Pan¹, Donghong Ding², Dominic Cuiuri¹, Huijun Li¹, Jing Xu³, John Norrish¹ - Show less +3 more•Institutions (3)

University of Wollongong¹, Foshan University², Tsinghua University³

01 Oct 2018-Journal of Manufacturing Processes

TL;DR: In this paper, the authors review the emerging research on wire arc additive manufacturing (WAAM) techniques and the commonly used metallic feedstock materials, and also provide a comprehensive over view of the metallurgical and material properties of the deposited parts.

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671 citations

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References

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Journal Article•DOI•

Additive manufacturing and its societal impact: a literature review

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Samuel H. Huang¹, Samuel H. Huang², Peng Liu², Peng Liu³, Abhiram Mokasdar², Liang Hou¹ - Show less +2 more•Institutions (3)

Xiamen University¹, University of Cincinnati², Jilin University³

01 Jul 2013-The International Journal of Advanced Manufacturing Technology

TL;DR: In this article, the societal impact of additive manufacturing from a technical perspective is reviewed, and an abundance of evidences are found to support the promises of additive-manufacturing in the following areas: (1) customized healthcare products to improve population health and quality of life, (2) reduced environmental impact for manufacturing sustainability, and (3) simplified supply chain to increase efficiency and responsiveness in demand fulfillment.

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Abstract: Thirty years into its development, additive manufacturing has become a mainstream manufacturing process. Additive manufacturing build up parts by adding materials one layer at a time based on a computerized 3D solid model. It does not require the use of fixtures, cutting tools, coolants, and other auxiliary resources. It allows design optimization and the producing of customized parts on-demand. Its advantages over conventional manufacturing have captivated the imagination of the public, reflected in recent mainstream publications that call additive manufacturing “the third industrial revolution.” This paper reviews the societal impact of additive manufacturing from a technical perspective. Abundance of evidences were found to support the promises of additive manufacturing in the following areas: (1) customized healthcare products to improve population health and quality of life, (2) reduced environmental impact for manufacturing sustainability, and (3) simplified supply chain to increase efficiency and responsiveness in demand fulfillment. In the mean time, the review also identified the need for further research in the areas of life-cycle energy consumption evaluation and potential occupation hazard assessment for additive manufacturing.

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1,440 citations

"Additive manufacturing of metals" refers background in this paper

...Beyond that, they have the potential to significantly change complete value creation systems [1, 2]....
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Journal Article•DOI•

Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder

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Lore Thijs¹, Karolien Kempen¹, Jean-Pierre Kruth¹, Jan Van Humbeeck¹•Institutions (1)

Katholieke Universiteit Leuven¹

01 Mar 2013-Acta Materialia

TL;DR: In this paper, the high thermal gradients occurring during SLM lead to a very fine microstructure with submicron-sized cells, which can be modified to a weak cube texture along the building and scanning directions when a rotation of 90° of the scanning vectors within or between the layers is applied.

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1,431 citations

Journal Article•DOI•

Metal Fabrication by Additive Manufacturing Using Laser and Electron Beam Melting Technologies

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Lawrence E Murr¹, Sara M. Gaytan¹, D. A. Ramirez¹, E. Martinez¹, Jennifer Hernandez¹, Krista Amato¹, P. W. Shindo¹, Francisco Medina¹, Ryan B. Wicker¹ - Show less +5 more•Institutions (1)

University of Texas at El Paso¹

01 Jan 2012-Journal of Materials Science & Technology

TL;DR: In this paper, a comparative study of selective laser melting (SLM) and electron beam melting (EBM) is presented for the fabrication of complex, multi-functional metal or alloy monoliths by CAD-directed, selective melting of precursor powder beds.

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1,144 citations

"Additive manufacturing of metals" refers background in this paper

...By feeding helium to the work area during the melting process the pressure inside the system is increased to approximately 1 Pa so that electrical charging of the powder particles is avoided and heat conduction and cooling of the melt is enhanced [8,32]....
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...Using a high beam current of up to 30mA and a scan speed of about 104mm/s, temperatures of >700 C of the powder material are achieved for Ti-6Al-4V [8,35,36], while for e....
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...The operational atmosphere for the EBM process is basically a vacuum of <10 2 Pa [8]....
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...to about 102 mm/s and 5 mAe10 mA respectively during the subsequent melt scan with a certain scan sequence [8]....
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...Today, it has become possible to reliably manufacture dense parts with certain AM processes and for a number of materials, including steel, aluminium and titanium [8]....
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Book•

Powder metallurgy science

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Randall M. German

01 Jan 1984

1,138 citations

"Additive manufacturing of metals" refers background in this paper

...lable at ScienceDirect Contents lists avai Acta Materialia journal homepage: www.elsevier .com/locate/actamat By invitation only: overview article Additive manufacturing of metals Dirk Herzog a, *, Vanessa Seyda b, Eric Wycisk b, Claus Emmelmann a, b a Institute of Laser and System Technologies, Hamburg University of Technology, Germany b LZN Laser Zentrum Nord GmbH, Germany a r t i c l e i n f o Article history: Received 15 February 2016 Received in revised form 7 July 2016 Accepted 7 July 2016 Available online 20 July 2016 Keywords: Additive manufacturing Metals Microstructure Properties * Corresponding author....
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...According to German [45], an irregular, asymmetric particle shape is at a disadvantage of high packing density....
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Journal Article•DOI•

On the mechanical behaviour of titanium alloy TiAl6V4 manufactured by selective laser melting: Fatigue resistance and crack growth performance

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Stefan Leuders¹, M. Thöne¹, Andre Riemer¹, Thomas Niendorf¹, Thomas Tröster¹, Hans Albert Richard¹, Hans Jürgen Maier¹ - Show less +3 more•Institutions (1)

University of Paderborn¹

01 Mar 2013-International Journal of Fatigue

TL;DR: In this article, the microstructure-defect-property relationship under cyclic loading for a TiAl6V4 alloy processed by selective laser melting is investigated. And the results show that the micron sized pores mainly affect fatigue strength, while residual stresses have a strong impact on fatigue crack growth.

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1,079 citations