Hybrid additive manufacture of 316L stainless steel with cold spray and selective laser melting: Microstructure and mechanical properties

Yin, Shuo; Yan, Xingchen; Jenkins, R.G.; Chen, Chaoyue; Kazasidis, Marios; Liu, Min; Min, Kyoungwon; Lupoi, Rocco

doi:10.1016/j.jmatprotec.2019.05.029

Cited by 47 publications

(9 citation statements)

References 20 publications

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“…SLM samples presented a fracture surface composed of cleavage features with little dimples ( Figure 14 c,d), which coincided with other studies [ 59 ]. Compared with the DLD technique, a more fragile fracture due to its faster cooling is found, which provokes less ductility, as shown previously.…”

Section: Resultssupporting

confidence: 91%

Comparison of Different Additive Manufacturing Methods for 316L Stainless Steel

et al. 2021

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In additive manufacturing (AM), the technology and processing parameters are key elements that determine the characteristics of samples for a given material. To distinguish the effects of these variables, we used the same AISI 316L stainless steel powder with different AM techniques. The techniques used are the most relevant ones in the AM of metals, i.e., direct laser deposition (DLD) with a high-power diode laser and selective laser melting (SLM) using a fiber laser and a novel CO2 laser, a novel technique that has not yet been reported with this material. The microstructure of all samples showed austenitic and ferritic phases, which were coarser with the DLD technique than for the two SLM ones. The hardness of the fiber laser SLM samples was the greatest, but its bending strength was lower. In SLM with CO2 laser pieces, the porosity and lack of melting reduced the fracture strain, but the strength was greater than in the fiber laser SLM samples under certain build-up strategies. Specimens manufactured using DLD showed a higher fracture strain than the rest, while maintaining high strength values. In all the cases, crack surfaces were observed and the fracture mechanisms were determined. The processing conditions were compared using a normalized parameters methodology, which has also been used to explain the observed microstructures.

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Section: Resultssupporting

confidence: 91%

Comparison of Different Additive Manufacturing Methods for 316L Stainless Steel

et al. 2021

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“…repair of tools and high-value components, and not on developing hybrid components for new products and on issues associated with their scale-up manufacture (Reichler et al, 2019;Graf et al, 2012;Jones et al, 2012;Praniewicz et al, 2018). Usually, the reported research is limited to the fabrication of one hybrid component and not on their batch manufacture, whereas the underpinning methodologies cannot support their serial production (Yin et al, 2019). The selection of a suitable AM process for producing high-performance components while increasing the production rates and reducing the production cost is critical in developing multi-setup HM platforms.…”

Section: Introductionmentioning

confidence: 99%

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Mehmeti

Penchev

Lynch

et al. 2020

RPJ

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Purpose The paper reports an investigation into the mechanical behaviour of hybrid components produced by combining the capabilities of metal injection moulding (MIM) with the laser-based powder bed fusion (PBF) process to produce small series of hybrid components. The research investigates systematically the mechanical properties and the performance of the MIM/PBF interfaces in such hybrid components. Design/methodology/approach The MIM process is employed to fabricate relatively lower cost preforms in higher quantities, whereas the PBF technology is deployed to build on them sections that can be personalised, customised or functionalised to meet specific technical requirements. Findings The results are discussed, and conclusions are made about the mechanical performance of such hybrid components produced in batches and also about the production efficiency of the investigated hybrid manufacturing (HM) route. The obtained results show that the proposed HM route can produce hybrid MIM/PBF components with consistent mechanical properties and interface performance which comply with the American Society for Testing and Materials (ASTM) standards. Originality/value The manufacturing of hybrid components, especially by combining the capabilities of additive manufacturing processes with cost-effective complementary technologies, is designed to be exploited by industry because they can offer flexibility and cost advantages in producing small series of customisable products. The findings of this research will contribute to further develop the state of the art in regards to the manufacturing and optimisation of hybrid components.

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“…The traditional process of using cold spray coat transition elements like Al and Cu could be extended to heavy elements like Ni, and even additive manufacturing using cold spray [45] is a much-discussed topic in the industrial community as well. Few elements that could be sprayed with cold spray are Al, Cu, Ni, Ti, Ag, Zn, Ta, and Nb and their alloys as well as composites such as Cu-W, Al-SiC, and Al-Al 2 O 3 .…”

Section: Contribution Of Academia and Researchmentioning

confidence: 99%

Role of thermal spray in combating climate change

et al. 2021

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Thermal spraying is a scalable surface engineering technique used to add or to restore functionality of a solid surface by applying a coating. Examples of this include protection against wear, erosion, abrasion, and heat. In a specific sense, thermal spraying is particularly used to deposit thermal barrier coatings (TBCs) which finds use in transportation, power generation and automotive sector. As being a surface technique, thermal spraying much like other surface coating techniques can avoid the use of excessive bulk materials and in turn offers longevity to the life of the component, so it already contributes to the reduction of global warming by virtue of avoiding the use of excessive scarce materials and improving fuel efficiency. In terms of its contribution to the cause of global warming, thermal spraying stands in sharp contrast to the energy-intensive processes such as melting, casting, extrusion and welding. With the rise of additive manufacturing, it is possible to use thermal spray to complement that process in many ways and “cold spray additive manufacturing” (CSAM) is already gaining popularity. The thermal spraying technique relies on using selective types of gases—hydrogen being one of them and few types of metals/alloys which are now classed as critical raw materials due to them being on the supply risk register. Efforts to consider recycling and reuse and to find alternatives to these are very timely to continue drawing the advantage of thermal spraying being a relatively green technique. In particular, the green energy initiatives and the drive to develop energy storage and battery technologies could challenge the supply of raw materials such as hydrogen gas and rare earth elements. This underlines the research and development need for alternate materials and processes to address the issue of climate change which is the major focal point of the COP 26 Summit at Glasgow in 2021. The combination of digital technologies and thermal spray coatings will reduce gas, powder and power consumption, which will make this manufacturing process even greener.

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Hybrid additive manufacture of 316L stainless steel with cold spray and selective laser melting: Microstructure and mechanical properties

Cited by 47 publications

References 20 publications

Comparison of Different Additive Manufacturing Methods for 316L Stainless Steel

Comparison of Different Additive Manufacturing Methods for 316L Stainless Steel

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Role of thermal spray in combating climate change

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