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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Open Access

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Journal Article•DOI•

Microstructure and mechanical properties of Al-12Si produced by selective laser melting: Effect of heat treatment

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Konda Gokuldoss Prashanth, Sergio Scudino, Hansjörg Klauss, Kumar Babu Surreddi¹, Lukas Löber, Zhi Wang, A. K. Chaubey, Uta Kühn, Jürgen Eckert² - Show less +5 more•Institutions (2)

Chalmers University of Technology¹, Dresden University of Technology²

10 Jan 2014-Materials Science and Engineering A-structural Materials Properties Microstructure and Processing

TL;DR: In this article, the effect of annealing on microstructure and related tensile properties is examined and the results demonstrate that the mechanical behavior of the Al-12Si SLM samples can be tuned within a wide range of strength and ductility through proper annesaling treatment.

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Abstract: Al-12Si specimens are produced by selective laser melting (SLM) from gas atomized powders. An extremely fine cellular structure is observed with residual free Si along the cellular boundaries. Room temperature tensile tests reveal a remarkable mechanical behavior: the samples show yield and tensile strengths of about 260. MPa and 380. MPa, respectively, along with fracture strain of ~3%. The effect of annealing on microstructure and related tensile properties is examined and the results demonstrate that the mechanical behavior of the Al-12Si SLM samples can be tuned within a wide range of strength and ductility through proper annealing treatment.

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612 citations

Journal Article•DOI•

Mechanical Properties of AlSi10Mg Produced by Selective Laser Melting

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

Katholieke Universiteit Leuven¹

01 Jan 2012-Physics Procedia

TL;DR: In this article, the authors investigated the properties of selective laser melting (SLM) for AlSi10Mg parts and compared them to those of conventionally cast AlSi 10Mg.

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607 citations

Journal Article•DOI•

Effect of build geometry on the β-grain structure and texture in additive manufacture of Ti6Al4V by selective electron beam melting

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Alphons A. Antonysamy¹, J. Meyer, Philip B. Prangnell²•Institutions (2)

GKN¹, University of Manchester²

01 Oct 2013-Materials Characterization

TL;DR: In this paper, the effect of geometry on the variability in the grain structure and texture, seen in Tisingle bond6Al single bond4V alloy components produced by Selective Electron Beam Melting (SEBM), has been investigated.

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570 citations

"Additive manufacturing of metals" refers background in this paper

...LBM of Ti-6Al4V [25] and Ta [113], EBM [36] and LMD [2] (both Ti-6Al-4V), yielding grain sizes in build direction that exceed layer thickness....
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...Afterwards, as the build temperature is in the same range as the martensite start temperature Ms, the b-phase may transform diffusionless to a0 if below Ms and then decompose to a, or transform diffusional into a if above Ms [36]....
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...The bulk material generated by in-fill hatching showed the highly textured, coarse prior-b-grains directed parallel to the build direction, as described above [36]....
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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 skin contour however showed a complex structure consisting of an outer layer of fine-curved b-grains which nucleated from the surrounding powder bed and then growing inwards following the curvature of the melt pool, and an inner layer of lath shaped grains growing upwards from previously deposited material [36]....
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Journal Article•DOI•

Microstructure and tensile properties of selectively laser-melted and of HIPed laser-melted Ti–6Al–4V

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Chunlei Qiu¹, Nicholas J.E. Adkins¹, Moataz M. Attallah¹•Institutions (1)

University of Birmingham¹

20 Aug 2013-Materials Science and Engineering A-structural Materials Properties Microstructure and Processing

TL;DR: In this article, the tensile properties measured before and after HIPing were analyzed using optical microscopy, scanning electron microscopy (SEM) and X-ray diffraction (XRD).

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Abstract: Ti–6Al–4V samples have been prepared by selective laser melting (SLM) with varied processing conditions. Some of the samples were stress-relieved or hot isostatically pressed (HIPed). The microstructures of all samples were characterised using optical microscopy (OM), scanning electron microscopy (SEM) and X-ray diffraction (XRD) and the tensile properties measured before and after HIPing. It was found that the porosity level generally decreased with increase of laser power and laser scanning speed. Horizontally built samples were found to have a higher level of porosity than vertically built samples. The as-fabricated microstructure was dominated by columnar grains and martensites. HIPing closed the majority of the pores and also fully transformed the martensite into α and β phases. The as-fabricated microstructure exhibits very high tensile strengths but poor ductility with elongation generally smaller than 10%. The horizontally built samples show even lower elongation than vertically built samples. HIPing considerably improved ductility but led to a reduction in strength. With HIPing, the SLMed samples were found to show tensile properties comparable with those thermomechanically processed and annealed samples.

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566 citations

"Additive manufacturing of metals" refers background or methods in this paper

...[97] showed that HIP is a suitable method to eliminate detrimental porosity....
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...[97] found the residual porosity in their investigations of LBM as-fabricated Ti-6Al-4V to be mainly spherical, and argued that most of the voids were not gas-filled as they did not re-open in subsequent heat treatments once closed by previous HIP....
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...[97] HIP (920 C/103 MPa/4 h) aþb 980 ± 30 1040 ± 30 12....
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...[97] found that HIP at 920 C for 4 h and a pressure of 103 MPa results in a transformation of the asfabricated martensitic microstructure into a and b phases while reducing porosity at the same time, cp....
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Journal Article•DOI•

High Power Selective Laser Melting (HP SLM) of Aluminum Parts

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D. Buchbinder¹, Henrich Schleifenbaum², Sebastian Heidrich², Wilhelm Meiners², Jan Bültmann¹ - Show less +1 more•Institutions (2)

RWTH Aachen University¹, Fraunhofer Society²

01 Jan 2011-Physics Procedia

TL;DR: In this article, the authors proposed an additive additive manufacturing (AM) technology that enables the production of light weight structured components with series identical mechanical properties without the need for part specific tooling or downstream sintering processes, etc.

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553 citations