Metal Matrix Composites Synthesized by Laser-Melting Deposition: A Review

Mahmood, Muhammad Arif; Popescu, Andrei C.; Mihailescu, Ion N.

doi:10.3390/ma13112593

Cited by 47 publications

(28 citation statements)

References 170 publications

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“…Among the developed LAM techniques, LMD has been widely used efficiently for the coating of a surface with a layer of ceramics and/or CMMCs. This process is usually carried out on the surfaces of bulk (new/worn-out) materials with the emphasis on enhancing the surface characteristics or obtaining the desired biological, frictional, or chemical characteristics for a given material [18]. Equipped with high energy density laser beams, LMD setups have demonstrated their capabilities to process materials with high hardness and elevated melting points.…”

Section: Laser Additive Manufacturing (Lam) Processes: Selective Lasementioning

confidence: 99%

“…This procedure is commonly known as "process optimization." Due to rapid heating and cooling involved in the LMD process, cracks are usually induced due to a huge thermal gradient inherent to the LMD process [18]. The advent of cracks leads to poor mechanical properties and a shorter life span of the deposited coating.…”

Section: Technique Illustration Referencesmentioning

confidence: 99%

“…It was found that hot-pressing, slip casting and sintering processes resulted in high cost and energy utilizations, while microcracks were observed due to grinding process. Recently, additive manufacturing (AM) has gained great attention and is still under continuous investigations in the case of ceramics and ceramic-reinforced MMCs-based coatings [18]. AM, as defined by the American Society for Testing and Materials (ASTM), is "a technique, opposite to the subtractive manufacturing processes, of joining materials to make a 3D object using a CAD model, generally layer upon layer" [19].…”

Section: Introductionmentioning

confidence: 99%

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Laser Coatings via State-of-the-Art Additive Manufacturing: A Review

et al. 2021

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Ceramics and ceramic-reinforced metal matrix composites (CMMCs) demonstrate high wear resistance, excellent chemical inertness, and exceptional properties at elevated temperatures. These characteristics are suitable for their utilization in biomedical, aerospace, electronics, and other high-end engineering industries. The aforementioned performances make them difficult to fabricate via conventional manufacturing methods, requiring high costs and energy consumption. To overcome these issues, laser additive manufacturing (LAM) techniques, with high-power laser beams, were developed and extensively employed for processing ceramics and ceramic-reinforced CMMCs-based coatings. In respect to other LAM processes, laser melting deposition (LMD) excels in several aspects, such as high coating efficiency and lower labor cost. Nevertheless, difficulties such as poor bonding between coating and substrate, cracking, and reduced toughness are still encountered in some LMD coatings. In this article, we review recent developments in the LMD of ceramics and CMMCs-based coatings. Issues and solutions, along with development trends, are discussed and summarized in support of implementing this technology for current industrial use.

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Section: Laser Additive Manufacturing (Lam) Processes: Selective Lasementioning

confidence: 99%

Section: Technique Illustration Referencesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Laser Coatings via State-of-the-Art Additive Manufacturing: A Review

et al. 2021

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“…One of the advantages of DLW methods over conventional manufacturing methods is that intricate geometries can easily be manufactured to encounter the requirements of a specific application. The following steps are followed in every DLW process [ 11 ]: A three-dimensional model is generated using CAD software. This CAD model is converted generally into “.STL” format.…”

Section: Introductionmentioning

confidence: 99%

3D Printing at Micro-Level: Laser-Induced Forward Transfer and Two-Photon Polymerization

Mahmood

Popescu

2021

Polymers

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Laser-induced forward transfer (LIFT) and two-photon polymerization (TPP) have proven their abilities to produce 3D complex microstructures at an extraordinary level of sophistication. Indeed, LIFT and TPP have supported the vision of providing a whole functional laboratory at a scale that can fit in the palm of a hand. This is only possible due to the developments in manufacturing at micro- and nano-scales. In a short time, LIFT and TPP have gained popularity, from being a microfabrication innovation utilized by laser experts to become a valuable instrument in the hands of researchers and technologists performing in various research and development areas, such as electronics, medicine, and micro-fluidics. In comparison with conventional micro-manufacturing methods, LIFT and TPP can produce exceptional 3D components. To gain benefits from LIFT and TPP, in-detail comprehension of the process and the manufactured parts’ mechanical–chemical characteristics is required. This review article discusses the 3D printing perspectives by LIFT and TPP. In the case of the LIFT technique, the principle, classification of derivative methods, the importance of flyer velocity and shock wave formation, printed materials, and their properties, as well as various applications, have been discussed. For TPP, involved mechanisms, the difference between TPP and single-photon polymerization, proximity effect, printing resolution, printed material properties, and different applications have been analyzed. Besides this, future research directions for the 3D printing community are reviewed and summarized.

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“…The LMD process promises manufacturing advantages in comparison with conventional approaches, including complex geometries, control of the heat-affected zone, and the removal of several technological steps from the manufacturing process. These factors establish LMD as a potential candidate for many aerospace, automobile, industrial, and biomedical applications [2]. The LMD manufacturing process uses a laser beam to liquefy the substrate's surface, and the powder particles are delivered into the melt pool from a powder feeding nozzle where they melt and rapidly solidify, forming a layer of bulk material.…”

Section: Introductionmentioning

confidence: 99%

Estimation of clad geometry and corresponding residual stress distribution in laser melting deposition: analytical modeling and experimental correlations

Mahmood

Popescu

Hapenciuc

et al. 2020

Int J Adv Manuf Technol

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Laser melting deposition (LMD) is a promising technology to produce net-shape parts. The deposited layers' characteristics and induced residual stress distribution influence the quality, mechanical, and physical properties of the manufactured parts. In this study, two theoretical models are presented. Initially, the clad geometry of the 1st deposited layer is estimated using the primary process parameters. Then, a hatch distance is used to calculate the re-melting depth and total clad geometry for all the deposited layers. The output of the 1st model is then used as an input in the 2nd model to estimate the residual stress distribution within the substrate and deposited layers. The model, for clad geometry, is validated using published experimental data for the depositions of AISI316L powder debits on AISI321 bulk substrate by the LMD process. For the residual stress distribution model validation, the published experimental results for X-ray diffractometry, in case of AISI4340 steel powder debits depositions on the AISI4140 bulk substrate by the LMD setup, are used. It was found that the current models can estimate the clad geometry and induced residual stress distribution with an accuracy of 10–15 % mean absolute deviation. An optimum selection of hatch distance is necessary for proper energy density utilization and dimensional control stability. The induced residual stress distribution was caused by the heating and cooling mechanisms, which appeared due to rapid heating and moderate cooling, in combination with slow conduction. These phenomena became incrementally iterative with the number of layers to be deposited, thus presenting a direct relationship between the residual stress distribution and the number of layers deposited on the substrate. The proposed models have high computational efficiency without restoring the meshing and iterative calculations. The high prediction accuracy and computational efficiency allow the presented model to investigate further the part distortion, part porosity, life-expectancy and mechanical properties of the part, and process parameter planning.

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Metal Matrix Composites Synthesized by Laser-Melting Deposition: A Review

Cited by 47 publications

References 170 publications

Laser Coatings via State-of-the-Art Additive Manufacturing: A Review

Laser Coatings via State-of-the-Art Additive Manufacturing: A Review

3D Printing at Micro-Level: Laser-Induced Forward Transfer and Two-Photon Polymerization

Estimation of clad geometry and corresponding residual stress distribution in laser melting deposition: analytical modeling and experimental correlations

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