Engineering › Mechanical Engineering

Additive Manufacturing Materials and Processes

Works Count: 52570

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Description

This cluster of papers focuses on the additive manufacturing of metallic components, particularly through processes such as selective laser melting and electron beam melting. The research covers aspects such as microstructure, mechanical properties, process parameters, and material characterization for various metal powders used in the additive manufacturing process.

Keywords

Additive Manufacturing; Metallic Components; Selective Laser Melting; Microstructure; Mechanical Properties; Process Parameters; Metal Powders; Electron Beam Melting; Material Characterization; Metal 3D Printing

An overview of Direct Laser Deposition for additive manufacturing; Part I: Transport phenomena, modeling and diagnostics

2015-07-20

Scott M. Thompson , Linkan Bian , Nima Shamsaei +1 more

A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties

2015-05-27

Eyitayo Olatunde Olakanmi , Robert F. Cochrane , Kenny Dalgarno

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Wire-feed additive manufacturing of metal components: technologies, developments and future interests

2015-05-08

Donghong Ding , Zengxi Pan , Dominic Cuiuri +1 more

Wire + Arc Additive Manufacturing

2015-05-18

Stewart Williams , Filomeno Martina , Adrian Addison +3 more

Depositing large components (>10 kg) in titanium, aluminium, steel and other metals is possible using Wire + Arc Additive Manufacturing. This technology adopts arc welding tools and wire as feedstock … Depositing large components (>10 kg) in titanium, aluminium, steel and other metals is possible using Wire + Arc Additive Manufacturing. This technology adopts arc welding tools and wire as feedstock for additive manufacturing purposes. High deposition rates, low material and equipment costs, and good structural integrity make Wire+Arc Additive Manufacturing a suitable candidate for replacing the current method of manufacturing from solid billets or large forgings, especially with regards to low and medium complexity parts. A variety of components have been successfully manufactured with this process, including Ti–6Al–4V spars and landing gear assemblies, aluminium wing ribs, steel wind tunnel models and cones. Strategies on how to manage residual stress, improve mechanical properties and eliminate defects such as porosity are suggested. Finally, the benefits of non-destructive testing, online monitoring and in situ machining are discussed.

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

2012-12-28

Lore Thijs , Karolien Kempen , Jean‐Pierre Kruth +1 more

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Selective laser melting of aluminium components

2010-10-09

Eleftherios Louvis , Peter Fox , Christopher J. Sutcliffe

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

2015-01-31

Beth Carroll , Todd Palmer , Allison M. Beese

Microstructures and mechanical behavior of Inconel 718 fabricated by selective laser melting

2012-03-01

Krista Amato , S.M. Gaytan , L.E. Murr +5 more

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing

2014-06-25

Wayne E. King , Holly D. Barth , Víctor Castillo +5 more

Analysis of defect generation in Ti–6Al–4V parts made using powder bed fusion additive manufacturing processes

2014-08-21

Haijun Gong , Khalid Rafi , Hengfeng Gu +2 more

A study of the microstructural evolution during selective laser melting of Ti–6Al–4V

2010-03-17

Lore Thijs , Frederik Verhaeghe , Tom Craeghs +2 more

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

2012-01-01

L.E. Murr , S.M. Gaytan , Diana A. Ramirez +6 more

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

2012-11-29

Stefan Leuders , M. Thöne , Andre Riemer +4 more

Additive manufactured AlSi10Mg samples using Selective Laser Melting (SLM): Microstructure, high cycle fatigue, and fracture behavior

2011-08-05

Erhard Brandl , Ulrike Heckenberger , Vitus Holzinger +1 more

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Heat treatment of Ti6Al4V produced by Selective Laser Melting: Microstructure and mechanical properties

2012-07-14

Bey Vrancken , Lore Thijs , Jean‐Pierre Kruth +1 more

Microstructures and Mechanical Properties of Ti6Al4V Parts Fabricated by Selective Laser Melting and Electron Beam Melting

2013-08-05

H. Khalid Rafi , N.V. Karthik , Haijun Gong +2 more

Selective laser melting of AlSi10Mg alloy: Process optimisation and mechanical properties development

2014-10-07

N. Read , Wei Wang , Khamis Essa +1 more

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Effect of the build orientation on the mechanical properties and fracture modes of SLM Ti–6Al–4V

2014-08-02

Marco Simonelli , Y. Y. Tse , Christopher Tuck

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As-Fabricated and Heat-Treated Microstructures of the Ti-6Al-4V Alloy Processed by Selective Laser Melting

2011-05-18

T. Vilaro , Christophe Colin , J.D. Bartout

Reducing porosity in AlSi10Mg parts processed by selective laser melting

2014-08-20

Nesma T. Aboulkhair , Nicola M. Everitt , Ian Ashcroft +1 more

Selective laser melting (SLM) is widely gaining popularity as an alternative manufacturing technique for complex and customized parts. SLM is a near net shape process with minimal post processing machining … Selective laser melting (SLM) is widely gaining popularity as an alternative manufacturing technique for complex and customized parts. SLM is a near net shape process with minimal post processing machining required dependent upon final application. The fact that SLM produces little waste and enables more optimal designs also raises opportunities for environmental advantages. The use of aluminium (Al) alloys in SLM is still quite limited due to difficulties in processing that result in parts with high degrees of porosity. However, Al alloys are favoured in many high-end applications for their exceptional strength and stiffness to weight ratio meaning that they are extensively used in the automotive and aerospace industries. This study investigates the windows of parameters required to produce high density parts from AlSi10Mg alloy using selective laser melting. A compromise between the different parameters and scan strategies was achieved and used to produce parts achieving a density of 99.8%.

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Densification behavior, microstructure evolution, and wear performance of selective laser melting processed commercially pure titanium

2012-05-01

Dongdong Gu , Yves‐Christian Hagedorn , Wilhelm Meiners +4 more

Residual stresses in selective laser sintering and selective laser melting

2006-10-01

Peter Mercelis , Jean‐Pierre Kruth

Purpose This paper presents an investigation into residual stresses in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this phenomenon. Design/methodology/approach First, the … Purpose This paper presents an investigation into residual stresses in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this phenomenon. Design/methodology/approach First, the origin of residual stresses is explored and a simple theoretical model is developed to predict residual stress distributions. Next, experimental methods are used to measure the residual stress profiles in a set of test samples produced with different process parameters. Findings Residual stresses are found to be very large in SLM parts. In general, the residual stress profile consists of two zones of large tensile stresses at the top and bottom of the part, and a large zone of intermediate compressive stress in between. The most important parameters determining the magnitude and shape of the residual stress profiles are the material properties, the sample and substrate height, the laser scanning strategy and the heating conditions. Research limitations/implications All experiments were conducted on parts produced from stainless steel powder (316L) and quantitative results cannot be simply extrapolated to other materials. However, most qualitative results can still be generalized. Originality/value This paper can serve as an aid in understanding the importance of residual stresses in SLS/SLM and other additive manufacturing processes involving a localized heat input. Some of the conclusions can be used to avoid problems associated with residual stresses.

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Single-crystal laser deposition of superalloys: processing–microstructure maps

2001-04-01

M. Gäumann , Cyrille Bezençon , Paula Canalís +1 more

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

2012-01-31

Dongdong Gu , Wilhelm Meiners , Konrad Wissenbach +1 more

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 … 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 processed components needs to be clarified. The present review initially defines LS/LM/LMD processes and operative consolidation mechanisms for metallic components. Powder materials used for AM, in the categories of pure metal powder, prealloyed powder and multicomponent metals/alloys/MMCs powder, and associated densification mechanisms during AM are addressed. An in depth review is then presented of material and process aspects of AM, including physical aspects of materials for AM and microstructural and mechanical properties of AM processed components. The overall objective is to establish a relationship between material, process, and metallurgical mechanism for laser based AM of metallic components.

Additive manufacturing of strong and ductile Ti–6Al–4V by selective laser melting via in situ martensite decomposition

2014-12-12

Wei Xu , Milan Brandt , Shoujin Sun +5 more

Laser and electron‐beam powder‐bed additive manufacturing of metallic implants: A review on processes, materials and designs

2015-10-21

Swee Leong Sing , Jia An , Wai Yee Yeong +1 more

Additive manufacturing (AM), also commonly known as 3D printing, allows the direct fabrication of functional parts with complex shapes from digital models. In this review, the current progress of two … Additive manufacturing (AM), also commonly known as 3D printing, allows the direct fabrication of functional parts with complex shapes from digital models. In this review, the current progress of two AM processes suitable for metallic orthopaedic implant applications, namely selective laser melting (SLM) and electron beam melting (EBM) are presented. Several critical design factors such as the need for data acquisition for patient-specific design, design dependent porosity for osteo-inductive implants, surface topology of the implants and design for reduction of stress-shielding in implants are discussed. Additive manufactured biomaterials such as 316L stainless steel, titanium-6aluminium-4vanadium (Ti6Al4V) and cobalt-chromium (CoCr) are highlighted. Limitations and future potential of such technologies are also explored.

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High Rate Thick Film Growth

1977-08-01

John A. Thornton

Review of selective laser melting: Materials and applications

2015-12-01

Chor Yen Yap , Chee Kai Chua , Zhili Dong +4 more

Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component … Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component is built by selectively melting and fusing powders within and between layers. The SLM technique is also commonly known as direct selective laser sintering, LaserCusing, and direct metal laser sintering, and this technique has been proven to produce near net-shape parts up to 99.9% relative density. This enables the process to build near full density functional parts and has viable economic benefits. Recent developments of fibre optics and high-power laser have also enabled SLM to process different metallic materials, such as copper, aluminium, and tungsten. Similarly, this has also opened up research opportunities in SLM of ceramic and composite materials. The review presents the SLM process and some of the common physical phenomena associated with this AM technology. It then focuses on the following areas: (a) applications of SLM materials and (b) mechanical properties of SLM parts achieved in research publications. The review is not meant to put a ceiling on the capabilities of the SLM process but to enable readers to have an overview on the material properties achieved by the SLM process so far. Trends in research of SLM are also elaborated in the last section.

An overview of Direct Laser Deposition for additive manufacturing; Part II: Mechanical behavior, process parameter optimization and control

2015-07-26

Nima Shamsaei , Aref Yadollahi , Linkan Bian +1 more

Mechanical behavior of additive manufactured, powder-bed laser-fused materials

2015-11-10

Todd M. Mower , Michael Long

Mechanical behavior of four metallic alloys fabricated with layered, laser-heated methods of additive manufacturing (AM) was compared to that of similar alloys produced with conventional methods (wrought and machined). AM … Mechanical behavior of four metallic alloys fabricated with layered, laser-heated methods of additive manufacturing (AM) was compared to that of similar alloys produced with conventional methods (wrought and machined). AM materials were produced by a leading commercial service provider, as opposed to incorporating material specimens produced by unique or specially-adapted equipment. The elastic moduli were measured in flexure, stress–strain characteristics were measured in tensile deformation, and fatigue strengths were measured in fully reversed bending. The effects of fabrication orientation, surface polishing, and hot isostatic pressing upon mechanical behavior were studied. The fatigue strengths exhibited by SLM AlSi10Mg and DMLS Ti6Al4V in the as-fabricated condition proved to be significantly inferior to that of conventional material. These lower fatigue strengths are a consequence of multiple fatigue cracks initiating at surface defects, internal voids and microcracks, and growing simultaneously during cyclic loading. Measured fatigue strengths of DMLS 316L and 17-4PH approached those of corresponding wrought materials when subjected to principal stresses aligned with the build planes. When cyclic stresses were applied across the build planes of the DMLS stainless steels, fatigue fractures often developed prematurely by separation of material. Post-processing the DMLS Ti6Al4V and SS316L with hot isostatic pressure elevated the fatigue strength significantly. Measurements of surface roughness with an optical profilometer, examinations of the material microstructures, and fractography contribute to an understanding of the mechanical behavior of the additive materials.

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

2015-12-01

Wayne E. King , A. T. Anderson , Robert M. Ferencz +4 more

The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts … The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this paper, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

Metal Additive Manufacturing: A Review of Mechanical Properties

2016-05-05

John J. Lewandowski , Mohsen Seifi

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 … 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, EBF 3 ). 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 orientation/build direction on properties, when available, are also provided, along with discussion of the potential source(s) (e.g., texture, microstructure changes, defects) of anisotropy in properties. Recommendations for additional work are also provided.

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

2016-01-23

Sarah Everton , Matthias Hirsch , Petros Stravroulakis +2 more

Lack of assurance of quality with additively manufactured (AM) parts is a key technological barrier that prevents manufacturers from adopting AM technologies, especially for high-value applications where component failure cannot … Lack of assurance of quality with additively manufactured (AM) parts is a key technological barrier that prevents manufacturers from adopting AM technologies, especially for high-value applications where component failure cannot be tolerated. Developments in process control have allowed significant enhancement of AM techniques and marked improvements in surface roughness and material properties, along with a reduction in inter-build variation and the occurrence of embedded material discontinuities. As a result, the exploitation of AM processes continues to accelerate. Unlike established subtractive processes, where in-process monitoring is now commonplace, factory-ready AM processes have not yet incorporated monitoring technologies that allow discontinuities to be detected in process. Researchers have investigated new forms of instrumentation and adaptive approaches which, when integrated, will allow further enhancement to the assurance that can be offered when producing AM components. The state-of-the-art with respect to inspection methodologies compatible with AM processes is explored here. Their suitability for the inspection and identification of typical material discontinuities and failure modes is discussed with the intention of identifying new avenues for research and proposing approaches to integration into future generations of AM systems.

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Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones

2016-02-23

Saad A. Khairallah , Andrew T. Anderson , Alexander M. Rubenchik +1 more

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Additive manufacturing of metallic components by selective electron beam melting — a review

2016-05-09

Carolin Körner

Selective electron beam melting (SEBM) belongs to the additive manufacturing technologies which are believed to revolutionise future industrial production. Starting from computer-aided designed data, components are built layer by layer … Selective electron beam melting (SEBM) belongs to the additive manufacturing technologies which are believed to revolutionise future industrial production. Starting from computer-aided designed data, components are built layer by layer within a powder bed by selectively melting the powder with a high power electron beam. In contrast to selective laser melting (SLM), which can be used for metals, polymers and ceramics, the application field of the electron beam is restricted to metallic components since electric conductivity is required. On the other hand, the electron beam works under vacuum conditions, can be moved at extremely high velocities and a high beam power is available. These features make SEBM especially interesting for the processing of high-performance alloys. The present review describes SEBM with special focus on the relationship between process characteristics, material consolidation and the resulting materials and component properties.

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Additive manufacturing of metals

2016-07-20

Dirk Herzog , Vanessa Seyda , Eric Wycisk +1 more

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Additive manufacturing of fatigue resistant materials: Challenges and opportunities

2017-01-05

Aref Yadollahi , Nima Shamsaei

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Effect of selective laser melting (SLM) process parameters on microstructure and mechanical properties of 316L austenitic stainless steel

2017-06-04

Erica Liverani , Stefania Toschi , Lorella Ceschini +1 more

Additive manufacturing of metallic components – Process, structure and properties

2017-10-12

T. DebRoy , Huiliang Wei , J.S. Zuback +7 more

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Additively manufactured hierarchical stainless steels with high strength and ductility

2017-10-30

Yinmin Wang , Thomas Voisin , Joseph T. McKeown +7 more

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Anisotropy and heterogeneity of microstructure and mechanical properties in metal additive manufacturing: A critical review

2017-11-12

Yihong Kok , Xipeng Tan , Pan Wang +4 more

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Dislocation network in additive manufactured steel breaks strength–ductility trade-off

2017-12-06

Leifeng Liu , Qingqing Ding , Yuan Zhong +7 more

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

2018-08-08

Bintao Wu , Zengxi Pan , Donghong Ding +4 more

A review of selective laser melting of aluminum alloys: Processing, microstructure, property and developing trends

2018-09-12

Jinliang Zhang , Bo Song , Qingsong Wei +2 more

Additive manufacturing of Ti6Al4V alloy: A review

2018-12-18

Shunyu Liu , Yung C. Shin

In this paper, the recent progress on Ti6Al4V fabricated by three mostly developed additive manufacturing (AM) techniques-directed energy deposition (DED), selective laser melting (SLM) and electron beam melting (EBM)-is thoroughly … In this paper, the recent progress on Ti6Al4V fabricated by three mostly developed additive manufacturing (AM) techniques-directed energy deposition (DED), selective laser melting (SLM) and electron beam melting (EBM)-is thoroughly investigated and compared. Fundamental knowledge is provided for the creation of links between processing parameters, resultant microstructures and associated mechanical properties. Room temperature tensile and fatigue properties are also reviewed and compared to traditionally manufactured Ti6Al4V parts. The presence of defects in as-built AM Ti6Al4V components and the influences of these defects on mechanical performances are also critically discussed.

Steels in additive manufacturing: A review of their microstructure and properties

2019-11-07

Priyanshu Bajaj , Avinash Hariharan , Achutha U Kini +3 more

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Additive manufacturing of ultrafine-grained high-strength titanium alloys

2019-12-04

Duyao Zhang , Dong Qiu , Mark A. Gibson +4 more

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Material-structure-performance integrated laser-metal additive manufacturing

2021-05-27

Dongdong Gu , Xinyu Shi , Reinhart Poprawe +3 more

Laser-metal additive manufacturing capabilities have advanced from single-material printing to multimaterial/multifunctional design and manufacturing. Material-structure-performance integrated additive manufacturing (MSPI-AM) represents a path toward the integral manufacturing of end-use components with … Laser-metal additive manufacturing capabilities have advanced from single-material printing to multimaterial/multifunctional design and manufacturing. Material-structure-performance integrated additive manufacturing (MSPI-AM) represents a path toward the integral manufacturing of end-use components with innovative structures and multimaterial layouts to meet the increasing demand from industries such as aviation, aerospace, automobile manufacturing, and energy production. We highlight two methodological ideas for MSPI-AM-"the right materials printed in the right positions" and "unique structures printed for unique functions"-to realize major improvements in performance and function. We establish how cross-scale mechanisms to coordinate nano/microscale material development, mesoscale process monitoring, and macroscale structure and performance control can be used proactively to achieve high performance with multifunctionality. MSPI-AM exemplifies the revolution of design and manufacturing strategies for AM and its technological enhancement and sustainable development.

Metal additive manufacturing in aerospace: A review

2021-07-24

Byron Blakey-Milner , Paul Gradl , Glen Snedden +6 more

Metal additive manufacturing involves manufacturing techniques that add material to produce metallic components, typically layer by layer. The substantial growth in this technology is partly driven by its opportunity for … Metal additive manufacturing involves manufacturing techniques that add material to produce metallic components, typically layer by layer. The substantial growth in this technology is partly driven by its opportunity for commercial and performance benefits in the aerospace industry. The fundamental opportunities for metal additive manufacturing in aerospace applications include: significant cost and lead-time reductions, novel materials and unique design solutions, mass reduction of components through highly efficient and lightweight designs, and consolidation of multiple components for performance enhancement or risk management, e.g. through internal cooling features in thermally loaded components or by eliminating traditional joining processes. These opportunities are being commercially applied in a range of high-profile aerospace applications including liquid-fuel rocket engines, propellant tanks, satellite components, heat exchangers, turbomachinery, valves, and sustainment of legacy systems. This paper provides a comprehensive review of metal additive manufacturing in the aerospace industry (from industrial/popular as well as technical literature). This provides a current state of the art, while also summarizing the primary application scenarios and the associated commercial and technical benefits of additive manufacturing in these applications. Based on these observations, challenges and potential opportunities are highlighted for metal additive manufacturing for each application scenario.

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On the role of melt flow into the surface structure and porosity development during selective laser melting

2015-06-12

Chunlei Qiu , Chinnapat Panwisawas , Robin Ward +3 more

In this study, the development of surface structure and porosity of Ti–6Al–4V samples fabricated by selective laser melting under different laser scanning speeds and powder layer thicknesses has been studied … In this study, the development of surface structure and porosity of Ti–6Al–4V samples fabricated by selective laser melting under different laser scanning speeds and powder layer thicknesses has been studied and correlated with the melt flow behaviour through both experimental and modelling approaches. The as-fabricated samples were investigated using optical microscopy (OM) and scanning electron microscopy (SEM). The interaction between laser beam and powder particles was studied by both high speed imaging observation and computational fluid dynamics (CFD) calculation. It was found that at a high laser power and a fixed powder layer thickness (20 μm), the samples contain particularly low porosity when the laser scanning speeds are below 2700 mm/s. Further increase of scanning speed led to increase of porosity but not significantly. The porosity is even more sensitive to powder layer thickness with the use of thick powder layers (above 40 μm) leading to significant porosity. The increase of porosity with laser scanning speed and powder layer thickness is not inconsistent with the observed increase in surface roughness complicated by increasingly irregular-shaped laser scanned tracks and an increased number of discontinuity and cave-like pores on the top surfaces. The formation of pores and development of rough surfaces were found by both high speed imaging and modelling, to be strongly associated with unstable melt flow and splashing of molten material.

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Optimizing a photon absorber using conformal cooling channels and additive manufacturing in copper.

2025-07-01

Younes Chahid , Carolyn Atkins , Stephen Hodbod +7 more

Many of the 70 synchrotron facilities worldwide are undergoing upgrades to their infrastructure to meet a growing demand for increased beam brightness with nanometre-level stability. These upgrades increase the mechanical … Many of the 70 synchrotron facilities worldwide are undergoing upgrades to their infrastructure to meet a growing demand for increased beam brightness with nanometre-level stability. These upgrades increase the mechanical and thermal challenges faced by beamline components, creating opportunities to apply novel methodologies and manufacturing processes to optimize hardware performance and beam accuracy. Absorbers are important beamline components that rely on water-cooled channels to absorb thermal energy from excess light caused by synchrotron radiation or photon beams created by insertion devices, all within a limited volume, to protect downstream equipment and ensure safe, reliable operation. Additive manufacturing (AM) has been shown to meet criteria relevant to synchrotron environments like leak tightness and vacuum compatibility. However, there is a research gap on the heat transfer and pressure drop impact of different AM conformal cooling channel geometries, as well as the print quality of AM copper parts using low-power infrared lasers and their compliance with absorber requirements. In this study, an intermediate model of a Diamond Light Source photon absorber was optimized to incorporate AM conformal cooling channels, leading to two concept designs named `Horizontal' and `Coil'. When compared with the baseline design, the lightweight Horizontal concept performed the best in this study, with simulations showing a maximum temperature drop of 11%, a calculated pressure drop reduction of 82%, a mass reduction of 86%, and the consolidation of 21 individually brazed pipes into a single manifold. The AM print quality and compliance with the synchrotron environment was examined by producing custom benchmark artefacts and measuring their surface roughness, dimensional accuracy and porosity levels, which are characteristics that can affect heat absorption, structural integrity, thermal conductivity and vacuum performance. The study demonstrates the benefits and addresses outstanding challenges in reducing thermal fatigue, as well as the size, vibrations and energy consumption of AM absorbers.

A Review of Materials for Vehicle Structure Based on Specific Strength and Fatigue

2025-06-25

Ou Yang Kun , Guan Yu Wang , Ying Qiao Liu +2 more | Materials science forum

In today's changing times, more and more people will use automobiles to get around, and this will consume a lot of natural resources to supply cars, in order to make … In today's changing times, more and more people will use automobiles to get around, and this will consume a lot of natural resources to supply cars, in order to make energy efficiency, reducing the overall weight of the automobile is a direct way to reduce the weight of the automobile, and we need to use materials that can make the weight lighter while maintaining a certain level of strength. This review paper explores the properties of five custom materials: aluminum alloys, magnesium alloys, titanium alloys, carbon fiber, and ceramics. By comparing specific strengths and fatigue resistance, researchers found that customizing aluminum alloy are the most suitable materials for improving energy efficiency and reducing total vehicle weight, while still maintaining a certain level of stiffness. According to the data on the specific strength and fatigue resistance of aluminum alloy, it reaches conclusion that custom aluminum alloys can be used in the design of automotive vehicles as a function of improving fuel efficiency by reducing weight.

Thermo-Mechanical Modeling and Experimental Validation of Residual Stresses in ER70S-6 Component Manufactured by WAAM Process

2025-06-25

Deepak Kumar Gupta , Rahul S. Mulik | Welding in the World

Advances in the Additive Manufacturing of Superalloys

2025-06-25

Antonio del Bosque , Pablo Fernández‐Arias , Diego Vergara | Journal of Manufacturing and Materials Processing

This study presents a bibliometric analysis of the evolution and research trends in the additive manufacturing (AM) of superalloys over the last decade (2015–2025). The review follows a structured methodology … This study presents a bibliometric analysis of the evolution and research trends in the additive manufacturing (AM) of superalloys over the last decade (2015–2025). The review follows a structured methodology based on the PRISMA 2020 protocol, utilizing data from the Scopus and Web of Science (WoS) databases. Particular attention is devoted to the intricate process–structure–property relationships and the specific behavioral trends associated with different superalloy families, namely Ni-based, Co-based, and Fe–Ni-based systems. The findings reveal a substantial growth in scientific output, with the United States and China leading contributions and an increasing trend in international collaboration. Key research areas include process optimization, microstructural evolution and control, mechanical property assessment, and defect minimization. The study highlights the pivotal role of technologies such as laser powder bed fusion, electron beam melting, and directed energy deposition in the fabrication of high-performance components. Additionally, emerging trends point to the integration of machine learning and artificial intelligence for real-time quality monitoring and manufacturing parameter optimization. Despite these advancements, challenges such as anisotropic properties, porosity issues, and process sustainability remain critical for both industrial applications and future academic research in superalloys.

Microstructure and Correlation of Fracture Strength on Additively Processed Nuclear Grade Stainless Steel under Monotonic Load

2025-06-24

Dhinakaran Veeman , M. K. Das , Kanishkaa Jeevaraj +4 more | steel research international

Wire arc additive manufacturing (WAAM) emerges as a promising technique for fabricating nuclear‐grade stainless steel (SS) components with complex geometries and strong mechanical performance. Herein, SS347 is successfully deposited using … Wire arc additive manufacturing (WAAM) emerges as a promising technique for fabricating nuclear‐grade stainless steel (SS) components with complex geometries and strong mechanical performance. Herein, SS347 is successfully deposited using WAAM to fabricate a defect‐free wall structure and fracture strength is evaluated using single‐edge notch bend (SENB) test. Fracture strength of WAAM‐fabricated SS347 is found to be 209.26 MPa√m, which is ≈8.3% higher than that of wrought (WR) SS347 counterpart (191.74 MPa√m), primarily due to microstructural anisotropy and residual stress effects inherent to the additive process. Detailed microstructural analysis reveals the presence of elongated columnar grains, NbC precipitates, and localized knife‐line attack zones, all of which significantly influence crack initiation and propagation paths. Crack behavior is further analyzed using generalized finite element method (GFEM), which successfully simulates crack growth stages with a deviation of less than 2.5% from experimental results. The study underscores the viability of WAAM for fabricating SS347 components suitable for nuclear pressure vessel application and validates GFEM as a reliable tool for predicting fracture performance in additively manufactured metallic structures.

Numerical simulation of temperature field and microstructure of duplex stainless steel arc additive manufacturing process

2025-06-24

Wei Xu , Kaikui Zheng , Chuanxu Yao | Journal of Materials Science

Holistic Quality Assessment of Additively Manufactured Heat Exchangers Using Robotic CT

2025-06-24

Jitendra Singh Rathore , M.H. Costin , Quynh Trang Pham +3 more | e-Journal of Nondestructive Testing

The increasing demand for higher heat transfer efficiency has driven the integration of compact heat exchangers with additive manufacturing (AM). The ability to fabricate intricate geometries using diverse materials allows … The increasing demand for higher heat transfer efficiency has driven the integration of compact heat exchangers with additive manufacturing (AM). The ability to fabricate intricate geometries using diverse materials allows for optimized trade-offs between heat transfer and pressure drop. This work demonstrate a holistic quality inspection approach utilizing a robotic Computed Tomography (CT) setup for the comprehensive evaluation of various types of AM heat exchangers. Three distinct geometric designs-OSF, WAVY, and TPMS-were analyzed using representative mock-ups. For global inspection, full-part scanning was performed to assess geometrical deviations and conduct statistical wall thickness analyses. As depicted in Figure 1(a), some regions exhibited unmelted powder, impacting their efficiency; additionally, various small porosities were observed in another design type, as shown in Figure 1(b). A holistic wall thickness analysis on the fins was conducted (Figure 1(c)), enabling statistical evaluations of uniformity.

Improvement of Ductile-Brittle Transition Temperature in Reactor Pressure Vessel Steel Fabricated Using Powder Bed Fusion

2025-06-24

Wonjong Jeong , Young-Bum Chun , Suk Hoon Kang +2 more | MATERIALS TRANSACTIONS

On Interfacial Characterization and Thermodynamic Analysis of Ni-625-17-4 PH Stainless Steel-Based Functionally Graded Material Fabricated by Laser Powder Bed Fusion

2025-06-24

Bharat Kalia , Rupinder Singh , B. S. Pabla | Journal of The Institution of Engineers (India) Series C

Additive Manufacturing Method through Bead Overlap Optimization in Wire-Arc Directed Energy Deposition (DED)-Based Hot Forging Die Production

2025-06-24

Woo‐Jin Jeong , Hwi Jun Son , Chang Jong Kim +1 more | Journal of the Korean Society of Manufacturing Process Engineers

Analysis of gas-powder flow in multiangle laser cladding

2025-06-24

H.H. Fan , Zhiwen Wang , J.X. Liu +2 more | Journal of Laser Applications

Multiangle laser cladding, in which the cladding head is deflected at different angles, is an advanced surface modification technology that is widely used in the repair of metal parts with … Multiangle laser cladding, in which the cladding head is deflected at different angles, is an advanced surface modification technology that is widely used in the repair of metal parts with complex surfaces. Nevertheless, the powder flow was affected by gravity, causing decreasing powder utilization and degrading coating quality. In this paper, to reveal the gas-powder flow mechanism, the coupled models based on the computational fluid dynamics-discrete element method (CFD-DEM) were developed. They can consider not only the continuity characteristics of gas as a fluid, the discreteness characteristics of powder as particles, but also the mutual influence relationship. Subsequently, a series of simulations and experiments were conducted in which the cladding head was deflected at angles of 0°, 30°, 60°, 90°, 120°, and 150°. The results demonstrated that with the increase in the deflection angle, the maximum powder concentration gradually declined from 16.49 to 9.80 kg m−3, the diameter of the powder spot increased progressively from 2.66 to 5.31 mm, and the powder collection rate dropped significantly from 45.11% to 27.95%. Finally, the models were experimentally validated and proved to be accurate. The findings of this research revealed the mechanism of the gas-powder flow and provided theoretical guidance for the selection and optimization of process parameters in mutiangle laser cladding.

A novel pre-melted liquid filler laser directed energy deposition for Al alloy: Process behaviors and filler transfer characteristics

2025-06-24

Yu Mao , Hui Chen , Jun Xiong | International Journal of Heat and Mass Transfer

A comparative study of aluminium properties manufactured using additive friction stir deposition (AFSD) and wire arc additive manufacturing (WAAM)

2025-06-24

Numan Habib , Ana Vafadar , Ferdinando Guzzomi | Progress in Additive Manufacturing

Abstract Wire arc additive manufacturing (WAAM) has recently gained considerable attention due to its capability to manufacture large-size metal with a length of one meter or above, with good microstructural … Abstract Wire arc additive manufacturing (WAAM) has recently gained considerable attention due to its capability to manufacture large-size metal with a length of one meter or above, with good microstructural and mechanical properties. However, the manufacture of critical components exposed to extreme environmental conditions, such as high stresses, remains the focus of most research studies. The applications of WAAM in high-tech industries, such as aerospace and marine modes, remain limited due to metallurgical challenges such as oxidation, porosity, cracking, and deformation, especially for high-strength aluminium alloys, including 6XXX and 7XXX series. The aforementioned metallurgical challenges in WAAM are minimized to some extent by another emerging technology, known as additive friction stir deposition (AFSD). AFSD is capable of manufacturing large-size and high strength (strength equal to or greater than that of the raw material) industrial components with fewer metallurgical defects and refined microstructures. However, this technology is in its developmental stage and possesses some challenges, such as oxidation, which is currently an emerging topic for researchers in metal additive manufacturing (AM). This paper reviews the potential of various additive manufacturing (AM) techniques for the manufacture of high-strength components, using either unweldable virgin or recycled high-strength aluminium alloys. The study also provides a comprehensive overview of the importance of recycling aluminium, as well as the challenges of utilizing aluminium (Al) alloys within metal AM. Considerations related to microstructure, the mechanical properties and metallurgical defects in both these technologies are extensively discussed and compared. The study concludes that both technologies are still being developed and experience various metallurgical issues, which need to be addressed to fully utilize WAAM and AFSD for critical applications. Further, the AFSD process is shown to be a better alternative to the WAAM process in the fabrication of Al components, where it possesses less metallurgical issues, higher strength and more refined microstructures. The literature suggests ultimate tensile stress (UTS) and average elongation percentage during AFSD in the range of 197.3 MPa–306 MPa and 8.6%–39% for Al alloys, respectively. However, slightly better UTS values in the range of 344 MPa–349 MPa and significant reduction in average elongation percentage to 5% is noted during WAAM process. Furthermore, AFSD exhibited significantly higher microhardness values (40.8 HV–151.4 HV) when compared to WAAM (73 HV–111 HV). Accordingly, the study notes that further numerical and experimental studies are needed to fully understand material flow in stirring zones during the AFSD process.

Remarkable strengthening effects of cells in laser powder bed fusion-processed Inconel 718

2025-06-24

Taichi Kikukawa , Takuya Ishimoto , Hyoung Seop Kim +1 more | Materials Research Letters

Directional Effect of Plasticity Ball Burnishing on Surface Finish, Microstructure, Residual Stress and Hardness of Laser Direct Energy Deposited Stellite 21 Alloy

2025-06-23

Mohammad Uddin , J. Rech , Colin Hall +1 more | Materials

This paper investigates the effect of plasticity ball burnishing on characteristics of surface integrity, residual stress and hardness of laser direct energy deposited (DEDed) Stellite 21 alloys, with a focus … This paper investigates the effect of plasticity ball burnishing on characteristics of surface integrity, residual stress and hardness of laser direct energy deposited (DEDed) Stellite 21 alloys, with a focus on the burnishing directional effect on surface and microstructural deformation. The results demonstrated that the burnishing improved surface finish, reducing Sa and Sz by 24% and 47%, respectively. The burnishing flattened and modified the cellular/columnar grains at a depth of 50 µm, with the most notable changes observed on the cross-sectional plane normal to the burnishing direction. Compared to the ground surface, the burnishing introduced higher and deeper compressive stresses along normal to the burnishing/grinding direction (−1341 MPa and 61 µm) as compared to that along the burnishing direction (−449 MPa and 56 µm). Likewise, the burnishing increased the full width at half maximum (FWHM) in the same fashion by broadening XRD peaks along normal to the burnishing direction. Due to higher grain modification and dislocation density, the burnishing has improved microhardness at a depth of 320 µm by 26% along normal to the burnishing direction. These findings demonstrate that the plasticity ball burnishing has a directional effect on plastic deformation and can be considered a plausible technique for tailored surface integrity, residual stress and hardness, which potentially improve the service performance of DEDed Stellite 21 alloy components.

The Impact of As-Built Surface Characteristics of Selective-Laser-Melted Ti-6Al-4V on Early Osteoblastic Response for Potential Dental Applications

2025-06-23

Muhammad Hassan Razzaq , Olugbenga Ayeni , Selin Köklü +7 more | Journal of Functional Biomaterials

This study investigates the potential of Selective Laser Melting (SLM) to tailor the surface characteristics of Ti6Al4V directly during fabrication, eliminating the need for post-processing treatments potentially for dental implants. … This study investigates the potential of Selective Laser Melting (SLM) to tailor the surface characteristics of Ti6Al4V directly during fabrication, eliminating the need for post-processing treatments potentially for dental implants. By adjusting the Volumetric Energy Density (VED) through controlled variations in the laser scanning speed, we achieved customized surface textures at both the micro- and nanoscale levels. SLM samples fabricated at moderate VED levels (50–100 W·mm3/s) exhibited optimized dual-scale surface roughness—a macro-roughness of up to 25.5–27.6 µm and micro-roughness of as low as 58.8–64.2 nm—resulting in significantly enhanced hydrophilicity, with water contact angles (WCAs) decreasing to ~62°, compared to ~80° on a standard grade 5 machined Ti6Al4V plate. The XPS analysis revealed that the surface oxygen content remains relatively stable at low VED values, with no significant increase. The surface topography plays a significant role in influencing the WCA, particularly when the VED values are low (below 200 W·mm3/s) during SLM, indicating the dominant effect of surface morphology over chemistry in these conditions. Biological assays using osteoblast-like MG-63 cells demonstrated that these as-built SLM surfaces supported a 1.5-fold-higher proliferation and improved cytoskeletal organization relative to the control, confirming the enhanced early cellular responses. These results highlight the capability of SLM to engineer bioactive implant surfaces through process-controlled morphology and chemistry, presenting a promising strategy for the next generation of dental implants suitable for immediate placement and osseointegration.

Study on the Young's Modulus of Different Variants of IN718 Alloy in Additive Manufacturing and Traditional Manufacturing Using Interpretable Machine Learning Methods

2025-06-23

Wenzhao Li , Mingji Liu , Wen‐Ping Wu +1 more | Journal of Materials Engineering and Performance

On the high-temperature flow response of additive-manufactured and heat-treated Inconel 718 superalloy

2025-06-23

Muhammad Farhan Raza , Guney Guven Yapici | MRS Advances

Study of Processing Parameters and Aging Treatments on Relative Density and Microhardness of Additively Manufactured Maraging Steel

2025-06-23

Ola Jaballah , Narges Omidi , Asim Iltaf +2 more | SAE International Journal of Materials and Manufacturing

<div>This research examined maraging steel (C300), which is widely used in the automotive industry. The study investigated how various 3D printing parameters—laser power (P), scanning speed (V), and layer spacing … <div>This research examined maraging steel (C300), which is widely used in the automotive industry. The study investigated how various 3D printing parameters—laser power (P), scanning speed (V), and layer spacing (H)—as well as post-processing heat treatment factors such as time (t) and temperature (T) affect the properties of C300 steel produced via selective laser melting (SLM). The primary properties assessed included relative density, porosity, hardness, and microstructure. The first part of the analysis focused on how processing parameters, time, and temperature influenced porosity types and manufacturing defects. Subsequently, ANOVA was employed to explore the sensitivity of relative density and microhardness to these parameters. The results revealed an optimal combination of parameters that improved both microstructural and mechanical properties. Additionally, the post-processing heat treatment was found to impact microhardness by modifying the microstructure and martensite lath size, with both the processing parameters and treatments affecting the material’s porosity and relative density.</div>

Microstructural Evolution and Corrosion Behavior of Selective Laser Melted 17-4 pH Stainless Steel

2025-06-23

Roshan Maroti Vaghode , Anil Meena , Vijay Kumar Meena | Key engineering materials

17-4 Precipitation hardenable (PH) stainless steel (SS) is useful for applications that require a combination of high strength and corrosion resistance. However, when produced through selective laser melting (SLM), it … 17-4 Precipitation hardenable (PH) stainless steel (SS) is useful for applications that require a combination of high strength and corrosion resistance. However, when produced through selective laser melting (SLM), it has a distinct microstructure with significant composition and phase variations based on the process parameters and post processing heat treatment conditions. Therefore, the present study examines how process parameters, such as scanning speed and hatch distance, affect the microstructural, and corrosion characteristics of additively manufactured (AM) 17-4 PH stainless steel samples. Post-processing heat treatment resulted in a uniform and reproducible microstructure in SLM samples. Heat-treated AM samples were assessed in a 3.5 wt. % NaCl solution using electrochemical impedance spectroscopy (EIS). The specimen with an energy density of 39.06 J/mm³ exhibited the lowest open circuit potential value, indicating a favorable tendency to form a passive film. The sample with 66.96 J/mm³ exhibits enhanced corrosion resistance attributed to robust protective performance facilitated by a dense network of precipitates and finer grain size. This heightened resistance is further supported by the sample's highest corrosion layer resistance and charge transfer resistance.

Multiple data management for quality analysis in DED─LB⁄MW

2025-06-23

Jon Flores , David Alberdi , Itziar Cabanes +2 more | The International Journal of Advanced Manufacturing Technology

Abstract Directed energy deposition using laser beam and metal wire (DED─LB⁄MW) offers notable advantages for additive manufacturing (AM) of large metal components but remains limited by process variability and challenges … Abstract Directed energy deposition using laser beam and metal wire (DED─LB⁄MW) offers notable advantages for additive manufacturing (AM) of large metal components but remains limited by process variability and challenges in ensuring internal quality. This study presents an integrated multi-sensor monitoring approach combined with a spatiotemporal data fusion framework to enhance process understanding. Key thermal, geometric, and visual signals were acquired during deposition using a coaxial pyrometer, an optical coherence tomography (OCT) sensor, and a welding camera, and subsequently synchronized with robot trajectory data. Post-process computed tomography (CT) scans were used to incorporate internal porosity information. The fused dataset was mapped onto the manufactured geometry through a layer-wise 3D representation, enabling the spatial correlation of process features and defect formation. Results demonstrate that thermal accumulation, surface irregularities, and deficient bead overlap significantly affect deposition stability and internal quality. The proposed methodology supports advanced process analysis and lays the groundwork for data-driven control and quality assurance strategies in DED─LB⁄MW.

Numerical Simulation and Modeling of Powder Flow for Rectangular Symmetrical Nozzles in Laser Direct Energy Deposition

2025-06-23

Bin Hu , Junhua Wang , Li Zhang | Coatings

Wide-beam laser direct energy deposition (LDED) has been widely used due to its superior deposition efficiency. To achieve optimal laser-powder coupling, this technique typically employs rectangular powder nozzles. This study … Wide-beam laser direct energy deposition (LDED) has been widely used due to its superior deposition efficiency. To achieve optimal laser-powder coupling, this technique typically employs rectangular powder nozzles. This study establishes a simulation model to systematically investigate the powder flow field characteristics of rectangular symmetric nozzles. Through parametric analysis of powder feeding rate, carrier gas flow rate, and shielding gas flow rate, the effects on powder stream convergence behavior are quantitatively evaluated to maximize powder utilization efficiency. Key findings reveal that, while the powder focal plane position is predominantly determined by nozzle geometry, powder feeding parameters exhibit negligible influence on flow field intersections. The resulting powder spot demonstrates a rectangular profile slightly exceeding the laser spot dimensions, and the powder concentration exhibits a distinctive flat-top distribution along the laser’s slow axis, contrasting with a Gaussian distribution along the scanning direction. Experimental validation through powder collection tests confirms strong agreement with the simulation results. Furthermore, a mathematical model was developed to accurately describe the powder concentration distribution at the focal plane. These findings provide fundamental theoretical guidance for optimizing powder feeding systems in wide-beam LDED applications.

Машинное зрение в оценке in situ параметров неоднородности анизотропных изделий SLM в ходе растяжения

2025-06-22

А. Н. Чуканов , В. А. Коротков , Евгений Владимирович Цой +2 more | Чебышевский сборник

Предложена оригинальная методика расчёта in situ характеристик неоднородности анизотропных материалов на базе технологии машинного зрения (фотограмметрии). Объектами являлись образцы порошковых сплавов 316L и Inconel 718, изготовленные по технологии селективного лазерного … Предложена оригинальная методика расчёта in situ характеристик неоднородности анизотропных материалов на базе технологии машинного зрения (фотограмметрии). Объектами являлись образцы порошковых сплавов 316L и Inconel 718, изготовленные по технологии селективного лазерного сплавления (SLM) и подвергнутые равномерному одноосному растяжению.Методика базируется на совместном использовании в расчёте параметров кривыхупрочнения, построенных по результатам определения in situ интенсивностей истинныхнапряжений и деформаций в отдельных микрообъёмах образцов. В качестве таких микрообъёмов использовали поперечные сечения делительной сетки, нанесенной на поверхностьобразцов. Информацию о геометрии ячеек делительной сетки, изменявшуюся в процессерастяжения, получали в измерительном блоке из результатов фотограмметрии — измерений цифровых изображений делительной сетки, полученных в ходе фотофиксации образцапри растяжении.В расчётном блоке с помощью методики получены уравнения зависимостей показателя неоднородности материала по механическим свойствам и характеристики неравномерности его пластической деформации от интенсивностей действующих напряжений и деформаций.Применение математических алгоритмов оптимизации фотограмметрии и программирование блока расчётов на языке высокого уровня Python позволит автоматизироватьпроцесс расчёта полученных уравнений с входящими в них параметрами и в итоге создавать базы данных характеристик анизотропии и неоднородности свойств изделий, изготовленных методом SLM. Это обеспечит разработку теоретических основ для углублённого анализа и обоснованного прогнозирования влияния технологической анизотропии и неоднородности свойств изделий SLM на их работоспособность in situ.

Multi-sensor monitoring for optimising printing parameters of laser powder bed fusion (L-PBF) processes

2025-06-22

Allen Jun Wee Hum , Qingyang Lu , Truong Do +2 more | Virtual and Physical Prototyping

Effect of wide range of heat treatments on the corrosion resistance of additively manufactured 316L stainless steel (316L SS) via PBF-LB/M (powder bed fusion of metals using a laser beam)

2025-06-22

Tushar R. Dandekar , Ajay Kumar Essampally , Deepshree D. Awale +1 more | Progress in Additive Manufacturing

New Developments in the Field of Production and Application of Multi‐Material Wire Arc Additive Manufacturing Components: A Review

2025-06-21

Kai Treutler , Volker Wesling | Advanced Engineering Materials

It is evident that, due to the inherent process properties, arc‐based additive manufacturing offers the possibility of specifically applying locally different material properties (functional grading). One method of achieving this … It is evident that, due to the inherent process properties, arc‐based additive manufacturing offers the possibility of specifically applying locally different material properties (functional grading). One method of achieving this is to utilize a range of materials. Alternatively, the application of varying energy inputs has been demonstrated to yield different material properties. The scientific community is currently focusing on four core topics regarding multi‐material approaches in wire arc additive manufacturing. Firstly, the anisotropic behavior in the welding direction is presented. Secondly, the potential of employing materials with high plasticity to enhance local strength in components subjected to cyclic loading with locally notched components is a subject of discussion. The third research focus is on the influence of the production sequence on the local properties of surface layers in arc‐based production for specific corrosion and wear protection properties. The fourth and most extensive field pertains to the production of functional graded material systems for a wide range of applications. The present work aims to provide a comprehensive overview of the current state of research in these four research areas, with a view to establishing a connection to potential industrial applications. Moreover, it will furnish researchers with a range of new research perspectives.

AlSi10Mg honeycomb lattices produced by laser powder bed fusion: Mechanical, thermal, and microstructural performances

2025-06-21

Rabia Urkun , Dilşad Akgümüş Gök | Journal of Sandwich Structures & Materials

Lightweight lattice structures are increasingly used in various fields such as aerospace, automotive and biomedical due to their superior energy absorption capacity and high strength/weight ratio. In this study, honeycomb … Lightweight lattice structures are increasingly used in various fields such as aerospace, automotive and biomedical due to their superior energy absorption capacity and high strength/weight ratio. In this study, honeycomb lattice structures were designed and manufactured using AlSi10Mg alloy using Laser Powder Bed Fusion (LPBF) method. It was aimed to evaluate the mechanical, microstructural and thermal performances of these structures produced with LPBF method, which offers high precision and design flexibility. Compression and hardness tests, surface roughness measurements, density determination and microstructural analyzes such as Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM-EDS), Fourier Transform Infrared Spectroscopy (FTIR), Simultaneous Thermal Analysis with Thermogravimetric/Differential Scanning Calorimetry (STA, TG/DSC) and X-ray Diffraction (XRD) were applied to the produced samples. The obtained results revealed that there was a significant difference in terms of compressive strength between porous and dense structures; however, the hardness values were at similar levels. Microstructure analyses confirmed surface roughness and oxidation, as well as elemental distribution by EDS and the presence of α-Al and β-Mg 2 Si phases by XRD. Thermal analyses showed that the material exhibited good thermal stability with minimal mass loss at elevated temperatures. In general, it was concluded that AlSi10Mg honeycomb lattice structures produced by the LPBF method offer promising mechanical and thermal properties for applications requiring lightness and energy absorption.

Optimization of scanning path in laser powder bed fusion: training and application of deep learning model using small dataset

2025-06-21

Hubocheng Tang , Huilin Ren , Yi Xiong | Journal of Intelligent Manufacturing

Wire Arc Additive Manufacturing of Titanium Alloys for Enhancing Mechanical Properties and Grain-Refinement

2025-06-21

Gaurav Kishor , Krishna Kishore Mugada , Raju Prasad Mahto | Metals and Materials International

Cutting tool life prediction and extension through generative model-augmented deep learning and laser remanufacturing techniques

2025-06-21

Yuchen Liang , Yuqi Wang , Raymond Chiong +2 more | Engineering Applications of Artificial Intelligence

A New Sustainable Approach to Enhancing the Subtractive Process in the Additive–Subtractive Hybrid Manufacturing of AISI H13 Dry Machining

2025-06-21

Hiva Hedayati , Maryam Aramesh | Lubricants

In additive–subtractive hybrid manufacturing (ASHM), machining and additive processes are combined in a single operation to merge the benefits of both. This method faces challenges, especially during the machining steps. … In additive–subtractive hybrid manufacturing (ASHM), machining and additive processes are combined in a single operation to merge the benefits of both. This method faces challenges, especially during the machining steps. Parts made through additive manufacturing often have low machinability due to factors like residual stresses and fine, hard microstructures. In ASHM, intermediate heat treatments are not possible, leading to the increased hardness of the printed material. Cutting fluids, typically used to reduce temperature and friction, can contaminate the build environment and impair layer adhesion; therefore, they are not recommended in ASHM. This study investigates soft metallic lubricant coatings in ASHM as substitutes for conventional fluid lubricants during dry machining. The coatings form a lubricating layer between the tool and workpiece, providing an alternative to cutting fluids. This research evaluates their effectiveness in improving the surface integrity of additively manufactured parts and supporting dry machining. The results of our research show a 65% reduction in force, a 50% reduction in tool wear, and a reduction in microstructural changes during machining while maintaining dry machining.

Optimization of Additive Manufacturing Process for High-Precision Metal Parts

2025-06-20

Kai Zhang | Applied and Computational Engineering

This study focuses on the optimization of additive manufacturing process for high-precision metal parts, and analyzes in-depth the problems of precision deviation, unstable material properties, and low production efficiency in … This study focuses on the optimization of additive manufacturing process for high-precision metal parts, and analyzes in-depth the problems of precision deviation, unstable material properties, and low production efficiency in the application of the current technology. Through the systematic study of key process parameters, material properties and post-processing technologies in the additive manufacturing process, this paper proposes a set of process optimization solutions that include innovative methods such as dynamic regulation of laser power, multi-angle scanning strategy and gradient heat treatment. The experimental results show that the optimized additive manufacturing process can improve the dimensional accuracy of metal parts by 28% and reduce the surface roughness to below Ra 3.2 m, while the mechanical properties of the material reach more than 92% of those of the traditional manufacturing method. The research results provide theoretical basis and practical guidance for the additive manufacturing of high-precision metal parts, which is of great significance for promoting the application of advanced manufacturing technology in aerospace, medical devices and other high-end equipment manufacturing fields.

Enhancing Fatigue Life of Metal Parts Produced by High-Speed Laser Powder Bed Fusion Through In Situ Surface Quality Improvement

2025-06-20

Daniel Ordnung , Mirko Sinico , T. Mertens +2 more | Journal of Manufacturing and Materials Processing

The poor surface quality of the metal parts produced by laser powder bed fusion limits their application in load-bearing components, as it promotes crack initiation under cyclic loadings. Consequently, improving … The poor surface quality of the metal parts produced by laser powder bed fusion limits their application in load-bearing components, as it promotes crack initiation under cyclic loadings. Consequently, improving part quality relies on time-consuming surface finishing. This work explores a dual-laser powder bed fusion strategy to simultaneously improve the productivity, surface quality, and fatigue life of parts with inclined up-facing surfaces made from a novel tool steel. This is achieved by combining building using a high layer thickness of 120 μm with in situ quality enhancement through powder removal and laser remelting. A bending fatigue campaign was conducted to assess the performance of such treated samples produced with different layer thicknesses (60 μm, hull-bulk 60/120 μm, 120 μm) compared to as-built and machined reference samples. Remelting consistently enhanced the fatigue life compared to the as-built reference samples by up to a factor of 36. The improvement was attributed to the reduced surface roughness, the reduced critical stress concentration factors, and the gradually changing surface features with increased lateral dimensions. This led to a beneficial load distribution and fewer potential crack initiation points. Finally, the remelting samples produced with a layer thickness of 120 μm enhanced the fatigue life by a factor of four and reduced the production time by 30% compared to the standard approach using a layer thickness of 60 μm.

Influence of post-treatment on the performance of SLM forming 18ni300 electroplated coatings

2025-06-20

Wei Xu , Xiangli Liu , Yong Li +2 more | Research Square (Research Square)

<title>Abstract</title> Hot isostatic pressing (HIP) is widely used to enhance the intrinsic properties of additively manufactured 18Ni300 martensitic aging steel, which can eliminate internal defects and optimize the microstructure of … <title>Abstract</title> Hot isostatic pressing (HIP) is widely used to enhance the intrinsic properties of additively manufactured 18Ni300 martensitic aging steel, which can eliminate internal defects and optimize the microstructure of additively manufactured metals. However, there is still a lack of systematic knowledge about the influence of hot isostatic pressing on the interfacial properties of chromium plating on its surface, which makes it difficult to provide a reliable theoretical basis and process guidance for the precise optimization of plating properties under complex working conditions. In order to solve the above needs and technical problems, this paper centers on the post-treatment strengthening effect of chromium plating on the surface of additively manufactured 18Ni300 alloy to carry out in-depth investigation. Without post-treatment of pure chromium plating layer flatness and roughness degradation phenomenon obviously exists, through the XRD analysis to confirm that the composition of its physical phase contains Fe-Ni phase, FeNiCr phase and monolithic Cr residual phase. The microstructure response of chromium plating layer after heat treatment shows complex characteristics, transverse crack network and delamination phenomenon is triggered by the internal stress relaxation and crystal structure reconstruction of the plating layer. 600℃/70MPa hot isostatic pressing conditions, the plating layer surface flatness and interfacial straightness can be maintained, but there are still many internal pores, and densification needs to be improved. 1150℃/150MPa hot isostatic pressing process has a significant effect on the optimization of the performance of the layer: the surface flatness and interface straightening can be maintained, and the internal porosity still has more holes, and densification should be improved. The optimization effect is obvious: the surface flatness is well maintained; the interface with the substrate is formed; the hardness is greatly increased to 406.3-673.1HV0.2 ± 10%, and the monolithic phase disappears completely. The effective modulation of the atomic diffusion behavior at the plating-substrate interface by the hot isostatic pressing treatment was confirmed by the study: metallurgical bonding was strengthened; crack formation was suppressed; and the hardness and corrosion resistance were significantly improved. The results of the study open up an important new technological path for the optimization of surface protective layers of additively manufactured alloys.

Bio-tribo-corrosion behavior of additively manufactured Co-Cr dental implant alloy

2025-06-20

Neda Hashemi , Sh. Yahyavi , M. Moshkbar Bakhshayesh +2 more | Surface and Coatings Technology

Experimental study on laser cladding forming of 316 L stainless steels based on Response Surface Methodology

2025-06-20

Ran Feng , Zhukai Tang , Wai-Meng Quach +3 more | Structures

Passivity and breakdown mechanisms in laser powder bed fusion processed Ni-based Alloy 625: Influence of scan strategy

2025-06-20

Arshad Yazdanpanah , Mattia Franceschi , Gioele Pagot +7 more | Corrosion Science

Enhancement of Tribological Performance and Mitigation of Subsurface Damage in Selective Laser Melted Ti6Al4V alloy

2025-06-20

Asit Kumar Gain , Liangchi Zhang , Yaole Cui | Tribology International

Optimization of processing parameters in metal additive manufacturing

2025-06-20

Wei Huang | Research Square (Research Square)

<title>Abstract</title> Metal additive manufacturing (AM) has emerged as a transformative technology for producing complex geometries with tailored mechanical properties. However, achieving optimal part quality and performance requires precise control over … <title>Abstract</title> Metal additive manufacturing (AM) has emerged as a transformative technology for producing complex geometries with tailored mechanical properties. However, achieving optimal part quality and performance requires precise control over processing parameters such as laser power, scan speed, layer thickness, and hatch spacing. This study presents an analytical framework for predicting optimized processing parameters in metal AM, focusing on the interplay between thermal dynamics, microstructure evolution, and mechanical properties. The proposed approach integrates thermal modeling, solidification kinetics, and machine learning algorithms to identify optimized parameter sets that maximize mechanical strength. The framework is validated through experimental data from laser powder bed fusion (LPBF) of titanium alloys, demonstrating its capability to predict parameter combinations that yield superior part quality. This work provides a systematic pathway for accelerating the development of optimized metal AM processes, reducing trial-and-error experimentation, and enhancing the reliability of AM-produced components.

Physics-based analytical modeling of materials properties in metal additive manufacturing

2025-06-20

Wei Huang , Ruoqi Gao , Hamid Garmestani +1 more | Research Square (Research Square)

<title>Abstract</title> Emerging additive manufacturing (AM) offers a sustainable alternative to the subtractive processes with significant potential for complex geometries and material efficiency. However, predicting and controlling the microstructure-dependent properties of … <title>Abstract</title> Emerging additive manufacturing (AM) offers a sustainable alternative to the subtractive processes with significant potential for complex geometries and material efficiency. However, predicting and controlling the microstructure-dependent properties of AM parts, particularly metals, remains challenging due to complex multi-physical processes. This work develops a physics-based analytical modeling framework to predict the evolution of key microstructural features (texture and grain size) and their influence on material properties (elastic modulus, Poisson’s ratio, yield strength) in laser powder bed fusion (LPBF) of Ti-6Al-4V. The framework integrates: (1) a 3D thermal profile model with boundary heat transfer for a moving point heat source; (2) Johnson-Mehl-Avrami-Kolmogorov (JMAK) kinetics and Green’s function-based thermal stress analysis for grain size prediction during heating and cooling; (3) columnar-to-equiaxed transition (CET) criteria and Bunge calculation for multi-phase texture evolution; (4) a self-consistent model to predict texture-affected anisotropic elastic modulus and Poisson’s ratio; and (5) the Hall-Petch relation for grain size-dependent yield strength. Experimental validations confirm the fidelity of the thermal model (molten pool dimensions), texture simulation (pole figure intensities), and predicted properties. Crucially, the simulated effective elastic modulus (109-117 GPa) and yield strength (850-900 MPa) under consistent processing parameters align well with experimental ranges (100-140 GPa and 850-1050 MPa, respectively) and show stability regardless of layer or row settings. The Poisson’s ratio exhibits significant anisotropy (approx. 0.45-0.5 in X/Y vs. lower values in other directions). By bridging processing parameters, microstructure evolution, and final properties, this work provides a paradigm for computationally efficient prediction and optimization of AM material performance, paving the way for inverse design strategies.

Optimization of the heat treatment strategy for Inconel 718 superalloy produced by laser powder bed fusion additive manufacturing process

2025-06-20

Aman Dwivedi , Manoj Kumar Khurana | Materials Science and Technology

This study investigates the impact of heat treatments on the microstructure and mechanical properties of Inconel 718 components fabricated by Laser Powder Bed Fusion (LPBF). To address residual stresses and … This study investigates the impact of heat treatments on the microstructure and mechanical properties of Inconel 718 components fabricated by Laser Powder Bed Fusion (LPBF). To address residual stresses and microstructural inhomogeneities caused by rapid thermal cycles, three sequential treatments homogenization heat treatment (HHT), solution heat treatment (SHT), and aging heat treatment (AHT) were applied. Using a multi-objective Response Surface Method (RSM), heat treatment parameters were optimized. HHT was conducted at 1080 °C for 1–8 h, followed by SHT (980–1140 °C for 1 h) and standard AHT. Results revealed that a 2-h HHT led to optimal mechanical performance and a refined, uniform microstructure by redistributing Nb and Ti precipitates from the γ-matrix, enhancing the alloy's strength and service capability.

Effect of unit cell size on the microstructure and mechanical properties of Ti-6Al-4 V TPMS structures manufactured by selective laser melting

2025-06-19

Xinyu Zhang , Chun Guo , Wenqing Li +3 more | Canadian Metallurgical Quarterly

Influence of Laser Beam Shape and Post Heat-Treatment on the Microstructure and Mechanical Properties of Nickel-based Alloy IN718 Manufactured by Laser Powder Bed Fusion

2025-06-19

Matjaž Godec , Narges Mirzabeigi , Črtomir Donik +7 more | Journal of Materials Research and Technology

Evaluation of the Suitability of High-Temperature Post-Processing Annealing for Property Enhancement in LPBF 316L Steel: A Comprehensive Mechanical and Corrosion Assessment

2025-06-19

B.V. Efremenko , Yu. G. Chabak , Ivan Petryshynets +6 more | Metals

This study aims to comprehensively assess the suitability of post-processing annealing (at 900–1200 °C) for enhancing the key properties of 316L steel fabricated via laser powder bed fusion (LPBF). It … This study aims to comprehensively assess the suitability of post-processing annealing (at 900–1200 °C) for enhancing the key properties of 316L steel fabricated via laser powder bed fusion (LPBF). It adopts a holistic approach to investigate the annealing-driven evolution of microstructure–property relationships, focusing on tensile properties, nanoindentation hardness and modulus, impact toughness at ambient and cryogenic temperatures (−196 °C), and the corrosion resistance of LPBF 316L. Annealing at 900–1050 °C reduced tensile strength and hardness, followed by a moderate increase at 1200 °C. Conversely, ductility and impact toughness peaked at 900 °C but declined with the increasing annealing temperature. Regardless of the annealing temperature and testing conditions, LPBF 316L steel fractured through a mixed transgranular/intergranular mechanism involving dimple formation. The corrosion resistance of annealed steel was significantly lower than that in the as-built state, with the least detrimental effect being observed at 1050 °C. These changes resulted from the complex interplay of annealing-induced structural transformations, including elimination of the cellular structure and Cr/Mo segregations, reduced dislocation density, the formation of recrystallized grains, and the precipitation of nano-sized (MnCrSiAl)O3 inclusions. At 1200 °C, an abundant oxide formation strengthened the steel; however, particle coarsening, combined with the transition of (MnCrSiAl)O3 into Mo-rich oxide, further degraded the passive film, leading to a sharp decrease in corrosion resistance. Overall, post-processing annealing at 900–1200 °C did not comprehensively improve the combination of LPBF 316L steel properties, suggesting that the as-built microstructure offers a favorable balance of properties. High-temperature annealing can enhance a particular property while potentially compromising other performance characteristics.

Insights into laser powder bed fused β-type titanium alloy: Investigating corrosion behavior and wear properties after post-heat treatment

2025-06-19

Xuan Luo , Yuhao Li , Chao Yang +7 more | Journal of Materials Research and Technology

Enhanced fluid flow for defects reduction in laser cladding through laser shock modulation of molten pool

2025-06-19

Heng Lü , Yi He , Dong-Sheng Yang +2 more | International Journal of Heat and Mass Transfer

Enhancement of Wear Properties of Dissimilar SSDS 2507-IN718 Alloy Wall Via Ultrasonic Vibration Assisted Cold Metal Transfer Based Wire Arc Additive Manufacturing

2025-06-19

Rajendra Prasad , N. Yuvaraj , Vipin Vipin +1 more | Journal of Tribology

Abstract Cold Metal Transfer (CMT) has surfaced as an exceptionally promising technique for the direct production or repair of high-performance metal components. Induced fabrication defects, such as porosity and heterogeneous … Abstract Cold Metal Transfer (CMT) has surfaced as an exceptionally promising technique for the direct production or repair of high-performance metal components. Induced fabrication defects, such as porosity and heterogeneous microstructures, significantly influence the quality of parts and their mechanical performance. Ultrasonic vibration (UV) has been employed to improve the performance of components in the processes of solidifying melted materials. Limited research has been conducted on the application of UV in CMT-based wire arc direct energy deposition for the fabrication of dissimilar SDSS2507-IN718 components. This study introduces the application of UV-assisted CMT-based wire arc direct energy deposition for the production of dissimilar SDSS2507-IN718 components, aiming to reduce fabrication errors. Experimental investigations are conducted to analyze the effects of UV on the microstructures and wear characteristics of components produced through CMT. This manuscript outlines the findings regarding the wear characteristics of a dissimilar alloy wall produced through the UV-WAAM technique, which has been tested under dry sliding conditions with varying load conditions. Wear testing was performed in a dry, unlubricated setting utilizing a conventional high-load ball-on-disc tribometer. The wear rate and coefficient of friction are lower for samples treated with UV assistance compared to those treated with UV alone. The results indicated that the use of ultrasonic vibration enhanced the microstructure, resulting in an average grain size of 4.59 um. Furthermore, it successfully broke down the detrimental Laves precipitated phase into smaller particles that were uniformly dispersed.

Microstructure Evolution and Mechanical Property Enhancement of 30CrMnSiNi2A Steel Repaired by Laser Cladding with AerMet100 Steel

2025-06-19

Shaozhi Guan , Leilei Wang , Qiyu Gao +2 more | Metals and Materials International

A review of the impact of process parameters and post-process interventions on the mechanical properties and microstructure of stainless steel using selective laser melting

2025-06-19

D. Rajan Babu , Devendiran Sundararajan | Research Square (Research Square)

<title>Abstract</title> The Selective Laser Melting (SLM) technique possesses significant promise for producing distinctive 3D components of stainless steel, offering remarkable design flexibility for many industrial applications. In certain applications, porosity … <title>Abstract</title> The Selective Laser Melting (SLM) technique possesses significant promise for producing distinctive 3D components of stainless steel, offering remarkable design flexibility for many industrial applications. In certain applications, porosity and other flaws affected by process parameters may negatively affect the performance of manufactured components. Enhancement of mechanical and surface properties is necessary for numerous applications. Hence, the selection of Process parameters and post-processing procedures help in improving mechanical qualities and reducing metallurgical defects. The determination of this review is to offer a comprehensive account of the existing literature on Selective laser melted stainless steel, including selective laser melting process parameters optimization for the manufacture of Stainless-steel parts, focusing on improving part densification and achieving chosen microstructural morphologies. The impact of Various post-processing methods examined in significant research studies have been thoroughly analysed, revealing their effects on defects and the mechanical properties of selective laser melting-fabricated stainless-steel alloys. Numerous solutions have been discovered, among which have the form of optimizing the parameters of the process and also it helps better understanding of the Surface Enhancement and Material Property Improvement techniques used for post-processing. An extensive analysis of different energy-based surface finishing approaches, such as mechanical, chemical, and thermal procedures, shows increases in the strength, ductility, and surface roughness of stainless steel parts made using Selective laser melting.