Competition between densification and microstructure of functionalmaterials by Selective Laser Melting

Abstract

Functional materials like bulk metallic glasses (BMGs) and magnetocaloric materials (MCMs) are multi‐component alloys, possessing a unique combination of structural and functional properties. However, the complexity involved in manufacturing these materials limits their fabrication to rather simple shapes that are incapable of achieving full functionality. Laser‐based powder bed fusion (LPBF) or Selective Laser Melting (SLM) is an additive manufacturing (AM) technique that enables the fabrication of BMGs and MCGs in the form of complex shapes. However, high heating and cooling rates in SLM preclude complete amorphous phase formation (in BMGs) at higher energy densities that are essential for achieving a high relative density with minimal defects/pores. The optimization of process parameters and precursor powder characteristics have been the subject of intense research. The optimization is a must requirement to achieve the balance between high densification with no crystalline phase formation. The present review elaborates on the challenges concerning the SLM of BMGs and MCMs and addresses the current progress. The lack of sufficient studies on the SLM of MCMs presents several research opportunities. A summary of important outcomes and future prospects are discussed.

Evaluation of SFRP Lugs with SLM Bushing Load Capacity and Dependence of CZM Mode II Model Parameters on Embedded Elements Surface Roughness

“…Advances in additive manufacturing have enabled the use of reliable industrial lasers, highperformance software, cost-effective equipment, and advanced raw materials for aerospace manufacturing [43]. Selective laser manufacturing parts can achieve full compaction with minimal defects if process parameters are carefully optimized [44,45]. Thus, process parameters must be correctly selected for each new material system [46].…”

Modified Solution Annealing Heat Treatments of Powder Bed Fused Inconel 718

“…In [20], it was shown that optimum tensile strength required a different set of processing parameters than the set required for optimum density. Therefore, it is a challenging task to optimize the processing parameters to reduce all of these defects [21]. The bulk of the literature focuses on optimizing these processing parameters to produce fully or near fully dense parts [22][23][24][25].…”

Selective Laser Melting of Aluminum and Its Alloys

“…Hence, SLM is considered to allow for a considerable reduction in fuel emissions, which confers the process of an outstanding ecological performance making it a green technology for the future [ 30 ]. The SLM process has already made a considerable impact in the manufacturing, automobile, aerospace, pharmaceutical, electronics, and sports sectors [ 31 , 32 ] because of its ability to produce a wide variety of materials (metals, alloys, cermets, composites) without any theoretical restrictions [ 33 , 34 , 35 , 36 , 37 , 38 , 39 , 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 , 50 ].…”