On the current research progress of metallic materials fabricated by laser powder bed fusion process: a review

Abd‐Elaziem, Walaa; Elkatatny, Sally; Abd-Elaziem, Abd-Elrahim; Khedr, Mahmoud; El‐baky, Marwa A. Abd; Hassan, Mohamed A.; Abu–Okail, Mohamed; Mohammed, Moustafa M.; Järvenpää, Antti; Allam, Tarek; Hamada, Atef

doi:10.1016/j.jmrt.2022.07.085

Cited by 117 publications

(20 citation statements)

References 237 publications

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“…[ 13 ] The emergence of equiaxed grains in the L‐PBF process can be ascribed to the seamless heating and cooling rates encountered by the molten substance. [ 51 ] These equiaxed grains consist of an α‐Al phase decorated with a eutectic Si phase at their grain boundaries. The network‐like structure observed on the fabricated surface is attributed to the presence of the Si phase.…”

Section: Resultsmentioning

confidence: 99%

Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

Panda,

Sahoo,

Kumar

et al. 2024

Adv Eng Mater

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Metal‐based additive manufacturing can make complicated parts that are complex or expensive to cast and process. Rapid cooling rates increase L‐PBF’s mechanical properties during manufacturing. The objective of this study is to examine the impact of process parameters in the L‐PBF technique on the characteristics of microstructure and mechanical properties, specifically, on the nano‐hardness influenced by Si segregation. The microstructures of the produced specimens were examined using FESEM and the analysis identified the existence of bimodal equiaxed α‐Al grains, accompanied by Si phases located within their grain boundaries. In addition, the solidified sample exhibited the segregation of secondary precipitates, particularly , which resulted in enhanced mechanical properties. Both cellular walls and Si precipitates impede the motion and generation of dislocations, thereby influencing the overall behavior of dislocations. The examination of segregation at the top layer was conducted in a comprehensive manner, subsequently employing EDS for analysis. The presence of , , and other phases in all samples was confirmed through XRD. The as‐built samples’ residual stress under different process conditions was also investigated. In addition, a comparison was made between the obtained microstructure and a phase field model that was developed in order to forecast the evolution of the microstructure.This article is protected by copyright. All rights reserved.

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Section: Resultsmentioning

confidence: 99%

Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

Panda,

Sahoo,

Kumar

et al. 2024

Adv Eng Mater

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“…Particularly, Laser Powder Bed Fusion (LPBF) technology, based on powder bed melting, has emerged as a cutting-edge technique. It is capable of achieving smooth surfaces while reducing machining, increasing material utilization, and significantly shortening production cycles [18][19][20]. In addition, the rapid solidification process of alloys during the LPBF process refines grain structures, enhancing the overall mechanical properties, thus making it highly suitable for the near-net shaping of highstrength refractory metals and complex components [21,22].…”

Section: Introductionmentioning

confidence: 99%

Atomic-Scale Dislocation Structure Evolution and Crystal Ordering Analysis of Melting and Crystallization Microprocesses in Laser Powder Bed Melting of γ-TiAl Alloys

Gu,

Wang,

et al. 2024

Metals

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Laser Powder Bed Fusion (LPBF) technology exhibits significant advantages in the manufacturing of components with high dimensional accuracy and intricate internal cavities. However, due to the inherent room-temperature brittleness and high-temperature gradient induced by the laser forming process, the LPBF fabrication of γ-TiAl alloy is often accompanied by the initiation and propagation of defects. The aim of this study is to investigate the forming process of γ-TiAl alloy by the LPBF method through molecular dynamics simulation, and to explain the microparticle arrangement and displacement evolution of the melting and crystallization processes, thus elucidating the link between the variations in the laser process parameters and defect generation during microscopic laser heating. The results show that during the melting process, the peaks of the radial distribution function (RDF) decrease rapidly or even disappear due to laser heating, and the atomic disorder is increased. Although subsequent cooling crystallization reorders the atomic arrangement, the peak value of the RDF after crystallization is still 19.3% lower than that of the original structure. By setting different laser powers (200–800 eV/ps) and scanning speeds (0.2–0.8 Å/ps), the effects of various process parameters on microforming and defect evolution are clarified. When the laser power increases from 200 to 400 eV/ps, the stable value of atomic displacement rises from 6.66 to 320.87, while it rises from 300.54 to 550.14 when the scanning speed is attenuated from 0.8 to 0.4 Å/ps, which indicates that, compared with the scanning speed, the atomic mean-square displacements are relatively more sensitive to the fluctuation of laser power. Dislocation analysis reveals that a higher laser power significantly increases the cooling rate during the forming process, which further aggravates the generation and expansion of dislocation defects.

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“…Additive manufacturing technologies have emerged as an innovative industrial solution in recent decades, expanding to a wide range of applications. This is because of their ability to be used in manufacturing complex shapes and customised designs that are challenging to achieve using traditional technologies [12,13]. For all AM techniques, creating three-dimensional structures from a digitally created CAD model is achieved through the layer-by-layer printing of materials.…”

Section: Introductionmentioning

confidence: 99%

Tailoring 3D Star-Shaped Auxetic Structures for Enhanced Mechanical Performance

Wang,

Alsaleh,

Djuansjah

et al. 2024

Aerospace

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Auxetic lattice structures are three-dimensionally designed intricately repeating units with multifunctionality in three-dimensional space, especially with the emergence of additive manufacturing (AM) technologies. In aerospace applications, these structures have potential for use in high-performance lightweight components, contributing to enhanced efficiency. This paper investigates the design, numerical simulation, manufacturing, and testing of three-dimensional (3D) star-shaped lattice structures with tailored mechanical properties. Finite element analysis (FEA) was employed to examine the effect of a lattice unit’s vertex angle and strut diameter on the lattice structure’s Poisson’s ratio and effective elastic modulus. The strut diameter was altered from 0.2 to 1 mm, while the star-shaped vertex angle was adjusted from 15 to 90 degrees. Laser powder bed fusion (LPBF), an AM technique, was employed to experimentally fabricate 3D star-shaped honeycomb structures made of Ti6Al4V alloy, which were then subjected to compression testing to verify the modelling results. The effective elastic modulus was shown to decrease when increasing the vertex angle or decreasing the strut diameter, while the Poisson’s ratio had a complex behaviour depending on the geometrical characteristics of the structure. By tailoring the unit vertex angle and strut diameter, the printed structures exhibited negative, zero, and positive Poisson’s ratios, making them applicable across a wide range of aerospace components such as impact absorption systems, aircraft wings, fuselage sections, landing gear, and engine mounts. This optimization will support the growing demand for lightweight structures across the aerospace sector.

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On the current research progress of metallic materials fabricated by laser powder bed fusion process: a review

Cited by 117 publications

References 237 publications

Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

Investigating the Microstructural and Mechanical Characteristics of Laser Additive‐Manufactured AlSi10Mg Specimens Through Experimental and Phase‐Field Modeling Approaches

Atomic-Scale Dislocation Structure Evolution and Crystal Ordering Analysis of Melting and Crystallization Microprocesses in Laser Powder Bed Melting of γ-TiAl Alloys

Tailoring 3D Star-Shaped Auxetic Structures for Enhanced Mechanical Performance

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