A review on metallurgical aspects of laser additive manufacturing (LAM): Stainless steels, nickel superalloys, and titanium alloys

Moeinfar, Kh.; Khodabakhshi, F.; Kashani-Bozorg, S. F.; Mohammadi, Mohsen; Gerlich, A.P.

doi:10.1016/j.jmrt.2021.12.039

Cited by 101 publications

(26 citation statements)

References 232 publications

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“…In this regard, the metal microstructure can be directly controlled through the adjustment of the process parameters, which is indirectly the objective of many studies attempting to optimize the mechanical properties. Due to the unique microstructures in AM, some alloys manufactured via AM have comparable or superior mechanical strength compared to their conventionally manufactured counterparts (such as casting or wrought) [12,[97][98][99][100][101][102][103] [Figure 2E-F]. However, this rapid heating and cooling process generates high residual stresses in metal AM during fabrication, which may lead to warpage and cracking [19] .…”

Section: Optimal Processing Windowmentioning

confidence: 99%

Process parameter optimization of metal additive manufacturing: a review and outlook

Chia¹,

Wu²,

Wang³

et al. 2022

J Mater Inf

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The selection of appropriate process parameters is crucial in metal additive manufacturing (AM) as it directly influences the defect formation and microstructure of the printed part. Over the past decade, research efforts have been devoted to identifying "optimal" processing regimes for different materials to achieve defect-free manufacturing, which mostly involve costly trial-and-error experiments and computationally expensive mechanistic simulations. Hence, it is apropos to critically review the methods used to achieve the optimal process parameters in AM. This work seeks to provide a structured analysis of current methodologies and discuss systematic approaches toward general optimization work in AM and the process parameter optimization of new AM alloys. A brief review of process-induced defects due to process parameter selection is given and the current methods for identifying "optimal processing windows" are summarized. Research works are analyzed under a standard optimization framework, including the design of experiments and characterization, modelling and optimization algorithms. The research gaps that preclude multi-objective optimization in AM are identified and future directions toward optimization work in AM are discussed. With growing capabilities in AM, we should reconsider what the definition of the "optimal processing region".

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Section: Optimal Processing Windowmentioning

confidence: 99%

Process parameter optimization of metal additive manufacturing: a review and outlook

Chia¹,

Wu²,

Wang³

et al. 2022

J Mater Inf

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“…Regarding the non-sintering methodologies presented in ISO-ASTM 52900, AM processes involve power sources such as electron or laser beams, arc, and plasma [5] (pp. [3][4][5][6][7][8][9][10]. Based on the type of raw materials consumed, these AM processes can be classified into powder bed, direct powder feed (via coaxial nozzle), or wire feeding process.…”

Section: Introductionmentioning

confidence: 99%

“…Metals 2023, 13, x FOR PEER REVIEW 2 as electron or laser beams, arc, and plasma [5] (pp. [3][4][5][6][7][8][9][10]. Based on the type of raw m rials consumed, these AM processes can be classified into powder bed, direct powder (via coaxial nozzle), or wire feeding process.…”

Section: Introductionmentioning

confidence: 99%

“…Considerable research activity has been aimed at DLD manufacturing of nickel superalloys, which has inspired several reviews focusing on processing parameters, microstructural features, and mechanical properties [7][8][9][10][11][12]. However, considering the growing interest and rapid advancement in the development of DLD IN625 and IN625-based advanced composites, the literature asks for a quick update to cover emerging concepts and issues related to metallurgical features in AM material.…”

Section: Introductionmentioning

confidence: 99%

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A Review on Direct Laser Deposition of Inconel 625 and Inconel 625-Based Composites—Challenges and Prospects

Zafar

Emadinia

Conceição

et al. 2023

Metals

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The direct laser deposition (DLD) process has seen rigorous research in the past two decades due to its ability to directly manufacture products followed by minimal machining. The process input variables play a vital role in determining the properties achieved in the products manufactured by the DLD method. Inconel 625, a nickel-based superalloy with exceptional mechanical performance and corrosion resistance, has been used in critical applications within the aerospace, process, and marine industry. However, its poor machinability and higher load requirements for plastic deformation have been challenging for manufacturers. Therefore, many studies have explored the additive manufacturing of Inconel 625 to overcome these problems. This article focuses on the DLD of Inconel 625 and its composites, presenting the state-of-the-art, drawing a relation among laser processing parameters and resulting material properties, microstructure and phase evolution, and the high-temperature performance of DLD Inconel 625. The paper highlights the areas on which further studies may focus.

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“…In recent decades, the use of lasers in the surface engineering and powder melting of various materials has grown in importance [ 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 ]. Laser treatment is also successfully used in the case of titanium alloys.…”

Section: Introductionmentioning

confidence: 99%

Changes in the Laser-Processed Ti6Al4V Titanium Alloy Surface Observed by Using Raman Spectroscopy

et al. 2022

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This works reports on the effects of treating the surface of Ti6Al4V titanium alloy samples with a laser with a wavelength of 1064 nm, operating in a pulsed and continuous mode. The obtained surfaces with different roughness, complexity and wettability were examined by Raman spectroscopy in order to recognize the presence of titanium oxides on the functionalized surface. The layer of titanium oxides on the surface with the identified rutile phase obtained by laser treatment in the continuous wave mode is a reason for a hydrophobic surface that appeared 50 days after the treatment process. In the case of the surface obtained by the pulsed laser process, only local points at which the Raman bands attributed to the metastable phases anatase and brookite of TiO2 can be identified. In this treatment process, complete surface hydrophilicity was observed during 29 days after the functionalization process (maximal contact angle observed during this time was 68.4 deg). For some functionalization processes of different parameters, the contact angle remained immeasurable until 119 days after the functionalization process. In summary, Raman spectroscopy identifies surface changes of Ti6Al4V after laser processing.

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A review on metallurgical aspects of laser additive manufacturing (LAM): Stainless steels, nickel superalloys, and titanium alloys

Cited by 101 publications

References 232 publications

Process parameter optimization of metal additive manufacturing: a review and outlook

Process parameter optimization of metal additive manufacturing: a review and outlook

A Review on Direct Laser Deposition of Inconel 625 and Inconel 625-Based Composites—Challenges and Prospects

Changes in the Laser-Processed Ti6Al4V Titanium Alloy Surface Observed by Using Raman Spectroscopy

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