Laser additive manufacturing of metallic components: materials, processes and mechanisms

doi:10.1179/1743280411Y.0000000014

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Laser additive manufacturing of metallic components: materials, processes and mechanisms

Journal Article•DOI•

Laser additive manufacturing of metallic components: materials, processes and mechanisms

Dongdong Gu¹, Wilhelm Meiners¹, Konrad Wissenbach¹, R. Poprawe¹•Institutions (1)

Fraunhofer Society¹

01 May 2012-International Materials Reviews (Taylor & Francis)-Vol. 57, Iss: 3, pp 133-164

TL;DR: Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser as discussed by the authors, which is based on a novel materials incremental manufacturing philosophy.

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Abstract: Unlike conventional materials removal methods, additive manufacturing (AM) is based on a novel materials incremental manufacturing philosophy. Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser. The current development focus of AM is to produce complex shaped functional metallic components, including metals, alloys and metal matrix composites (MMCs), to meet demanding requirements from aerospace, defence, automotive and biomedical industries. Laser sintering (LS), laser melting (LM) and laser metal deposition (LMD) are presently regarded as the three most versatile AM processes. Laser based AM processes generally have a complex non-equilibrium physical and chemical metallurgical nature, which is material and process dependent. The influence of material characteristics and processing conditions on metallurgical mechanisms and resultant microstructural and mechanical properties of AM proc...

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Journal Article•DOI•

I and i

[...]

Kevin Barraclough

08 Dec 2001-BMJ

TL;DR: There is, I think, something ethereal about i —the square root of minus one, which seems an odd beast at that time—an intruder hovering on the edge of reality.

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Abstract: 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 …

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33,785 citations

Journal Article•

다중혈관 관상동맥 환자에서 y-문합을 이용하여 양쪽 내흉동맥만을 사용한 우회술의 조기 성적

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성기익, 이영탁, 박계현, 전태국, 박표원, 한일용, 장윤희 - Show less +3 more

01 Mar 2003-The Korean Journal of Thoracic and Cardiovascular Surgery

28,685 citations

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 "Laser additive manufacturing of met..."

...Lower linear heat inputs result in smaller melt pools, higher thermal gradients, and therefore fast cooling rates and fine microstructures, leading to higher yield and ultimate tensile strengths compared to components made with higher linear heat inputs [7,357,472,474]....
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Journal Article•DOI•

3D printing of polymer matrix composites: A review and prospective

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Xin Wang¹, Man Jiang², Zuowan Zhou², Jihua Gou¹, David Hui³ - Show less +1 more•Institutions (3)

University of Central Florida¹, Southwest Jiaotong University², University of New Orleans³

01 Feb 2017-Composites Part B-engineering

TL;DR: In this paper, the authors give an overview on 3D printing techniques of polymer composite materials and the properties and performance of 3D printed composite parts as well as their potential applications in the fields of biomedical, electronics and aerospace engineering.

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Abstract: The use of 3D printing for rapid tooling and manufacturing has promised to produce components with complex geometries according to computer designs. Due to the intrinsically limited mechanical properties and functionalities of printed pure polymer parts, there is a critical need to develop printable polymer composites with high performance. 3D printing offers many advantages in the fabrication of composites, including high precision, cost effective and customized geometry. This article gives an overview on 3D printing techniques of polymer composite materials and the properties and performance of 3D printed composite parts as well as their potential applications in the fields of biomedical, electronics and aerospace engineering. Common 3D printing techniques such as fused deposition modeling, selective laser sintering, inkjet 3D printing, stereolithography, and 3D plotting are introduced. The formation methodology and the performance of particle-, fiber- and nanomaterial-reinforced polymer composites are emphasized. Finally, important limitations are identified to motivate the future research of 3D printing.

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2,132 citations

Journal Article•DOI•

The metallurgy and processing science of metal additive manufacturing

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William J. Sames¹, Frederick Alyious List¹, Sreekanth Pannala¹, Ryan R. Dehoff¹, S. Suresh Babu² - Show less +1 more•Institutions (2)

Oak Ridge National Laboratory¹, University of Tennessee²

07 Mar 2016-International Materials Reviews

TL;DR: In this article, a review of additive manufacturing (AM) 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.

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Abstract: 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.

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1,713 citations

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References

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Open Access

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Book Chapter•DOI•

I and J

[...]

William Marsden

01 Jan 2012

139,059 citations

"Laser additive manufacturing of met..." refers background in this paper

...Theoretical and experimental studies by Kruth et al.249 have disclosed that the residual stress profile consists of two zones of large tensile stresses at the top and bottom of a LS/LM processed part, and a large zone of intermediate compressive stress in between....
[...]
...Theoretical and experimental studies by Kruth et al.(249) have disclosed that the residual stress profile consists of two zones of large tensile stresses at the top and bottom of a LS/LM processed part, and a large zone of intermediate compressive stress in between....
[...]
...Normally, the stresses are larger perpendicular to the scan direction than along the scan direction.(249) A subdivision of the surface in smaller sectors leads to a lower stress value....
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...As a general rule, a proper increase in the applied laser energy density leads to higher part density, as confirmed in Kruth et al.’s work128 on LM of Ti–6Al–4V (Fig....
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...In Kruth et al.,177 Zhu et al.47 and Gu et al.’s239 work, P element is added in the form of prealloyed Fe3P, SCuP and Cu3P to Fe based and Cu based powder systems, which are effective in enhancing wetting behaviour and LS densification....
[...]

Journal Article•DOI•

I and i

[...]

Kevin Barraclough

08 Dec 2001-BMJ

TL;DR: There is, I think, something ethereal about i —the square root of minus one, which seems an odd beast at that time—an intruder hovering on the edge of reality.

...read moreread less

33,785 citations

Journal Article•

다중혈관 관상동맥 환자에서 y-문합을 이용하여 양쪽 내흉동맥만을 사용한 우회술의 조기 성적

[...]

성기익, 이영탁, 박계현, 전태국, 박표원, 한일용, 장윤희 - Show less +3 more

01 Mar 2003-The Korean Journal of Thoracic and Cardiovascular Surgery

28,685 citations

"Laser additive manufacturing of met..." refers background in this paper

...The determination of absorptance of powders is particularly important to thermal development, because it allows one to determine a suitable processing window free of a non-response of powder due to an insufficient laser energy input or a pronounced material evaporation due to an excessive energy input.(235) The absorptance is defined as the ratio of the absorbed radiation to the incident radiation....
[...]
...The absorptance of pores approaches that of a grey body.(235) The absorptance of powders has a direct influence on the optical penetration depth d of the radiation, which is defined as the depth at which the intensity of the radiation inside the material falls to 1/e (y37%) of the original value....
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...Tolochko et al.(235) have experimentally determined the absorptance of a number of powders, with two different wavelengths of 1?06 and 10?6 mm obtained by Nd : YAG and CO2 lasers....
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...Tolochko et al.235 have experimentally determined the absorptance of a number of powders, with two different wavelengths of 1?...
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...The broadly recognised definition of balling effect is concluded as follows, combined the previous studies by Niu et al.,241 Tolochko et al.,80 Das165 and Simchi et al.61 During LS/LM, laser scanning is performed line by line and the laser energy causes melting along a row of powder particles, forming a continuous liquid scan track in a cylindrical shape....
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Book•

Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing

[...]

Ian Gibson, David W. Rosen, Brent Stucker

01 Jan 2009

TL;DR: Gibson et al. as discussed by the authors presented a comprehensive overview of additive manufacturing technologies plus descriptions of support technologies like software systems and post-processing approaches, and provided systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing.

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Abstract: Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing deals with various aspects of joining materials to form parts. Additive Manufacturing (AM) is an automated technique for direct conversion of 3D CAD data into physical objects using a variety of approaches. Manufacturers have been using these technologies in order to reduce development cycle times and get their products to the market quicker, more cost effectively, and with added value due to the incorporation of customizable features. Realizing the potential of AM applications, a large number of processes have been developed allowing the use of various materials ranging from plastics to metals for product development. Authors Ian Gibson, David W. Rosen and Brent Stucker explain these issues, as well as: Providing a comprehensive overview of AM technologies plus descriptions of support technologies like software systems and post-processing approaches Discussing the wide variety of new and emerging applications like micro-scale AM, medical applications, direct write electronics and Direct Digital Manufacturing of end-use components Introducing systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing is the perfect book for researchers, students, practicing engineers, entrepreneurs, and manufacturing industry professionals interested in additive manufacturing.

...read moreread less

3,087 citations

Book•

The physical properties of liquid metals

[...]

Roderick I. L. Guthrie, 孝道飯田

01 Jan 1988

TL;DR: A comprehensive survey of theories, empirical relations and experimental data on the physical properties of liquid metals can be found in this paper, where the authors give a comprehensive overview of liquid metal properties.

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Abstract: Virtually all metals are produced by a process involving a liquid stage. The microstructure, and hence macroscopic properties of the final solid metal, are heavily influenced by the properties of the liquid metal. A proper understanding of liquid metal properties is also essential for the efficient management of refining and alloying processes. This book gives a comprehensive survey of theories, empirical relations and experimental data on the physical properties of liquid metals.

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1,804 citations