Post-processing of additively manufactured metallic alloys – A review

Malakizadi, Amir; Mallipeddi, Dinesh; Dadbakhsh, Sasan; M’Saoubi, Rachid; Krajnik, Peter

doi:10.1016/j.ijmachtools.2022.103908

Cited by 98 publications

(20 citation statements)

References 244 publications

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“…Jan Kazior et al [ 147 ] have examined the properties of PH17-4 steel fabricated by the powder metallurgy method, and they found that adding temperature is a very sensitive parameter to obtain high strength with satisfactory ductility. Additive manufacturing (AM) approaches as disruptive technology [ 8 , 32 , 150 , 151 , 152 , 153 , 154 ], due to their near-net-shape feature, cost-effective, and customized flexible design for complicated parts, are widely introduced to prepare PHSS gradually across multi-industries. The processing methods of AM for PHSS are still in their infancy.…”

Section: Effects Of Different Preparation Methods On Microstructure A...mentioning

confidence: 99%

Recent Advances on Composition-Microstructure-Properties Relationships of Precipitation Hardening Stainless Steel

et al. 2022

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Precipitation hardening stainless steels have attracted extensive interest due to their distinguished mechanical properties. However, it is necessary to further uncover the internal quantitative relationship from the traditional standpoint based on the statistical perspective. In this review, we summarize the latest research progress on the relationships among the composition, microstructure, and properties of precipitation hardened stainless steels. First, the influence of general chemical composition and its fluctuation on the microstructure and properties of PHSS are elaborated. Then, the microstructure and properties under a typical heat treatment regime are discussed, including the precipitation of B2-NiAl particles, Cu-rich clusters, Ni3Ti precipitates, and other co-existing precipitates in PHSS and the hierarchical microstructural features are presented. Next, the microstructure and properties after the selective laser melting fabricating process which act as an emerging technology compared to conventional manufacturing techniques are also enlightened. Thereafter, the development of multi-scale simulation and machine learning (ML) in material design is illustrated with typical examples and the great concerns in PHSS research are presented, with a focus on the precipitation techniques, effect of composition, and microstructure. Finally, promising directions for future precipitation hardening stainless steel development combined with multi-scale simulation and ML methods are prospected, offering extensive insight into the innovation of novel precipitation hardening stainless steels.

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Section: Effects Of Different Preparation Methods On Microstructure A...mentioning

confidence: 99%

Recent Advances on Composition-Microstructure-Properties Relationships of Precipitation Hardening Stainless Steel

et al. 2022

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“…12. SUMMARY In summary, this article illustrates that there are complex interactions between the design and process parameters of AM processes, local thermal conditions, cooling rates and temperature gradients, the resulting material microstructure, porosity and residual stress state, the use of intermediate and heat treatment processes, and the process conditions in machining, which have a decisive effect on the final material and component properties in terms of strength, tribology and corrosion resistance [218]. A summary of the dependencies of several process steps in additive subtractive manufacturing chains is provided by Fig.…”

Section: The Functional Properties Of Am-partsmentioning

confidence: 99%

The Additive-Subtractive Process Chain - a Review

Möhring¹,

Maucher²,

Becker³

et al. 2023

Journal of Machine Engineering

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In recent years, metal additive manufacturing developed intensively and became a relevant technology in industrial production of highly complex and function integrated parts. However, almost all additively manufactured parts must be post-processed in order to fulfil geometric tolerances, surface quality demands and the desired functional properties. Thus, additive manufacturing actually means the implementation of additive-subtractive process chains. Starting with the most relevant additive processes (powder-based PBF-LB, LMD-p and wire-based WAAM and LMD-w/WLAM), considering intermediate process steps (heat treatment and shot peening) and ending up with post-processing material removal processes (with defined and undefined cutting edges), this paper gives an overview of recent research findings with respect to a comprehensive scientific investigation of influences and interactions within the additive-subtractive process chain. This includes both the macroscopic geometric scale and the microscopic scale of the material structure. Finally, conclusions and future perspectives are derived and discussed.

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“…Nevertheless, the large body of machining energy ends in unwanted heat, which could cause problems with surface integrity, surface cracking, and distortion [ 5 ]. In addition, residual stresses and burrs could also be generated during the machining process and predominantly require further post-processing steps [ 6 ]. In general, it is worth stating that superalloys with high strength and wear resistance are difficult to be machined using traditional machining processes, such as turning, drilling, shaping, and milling [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304

2023

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Its unexcelled mechanical and physical properties, in addition to its biocompatibility, have made stainless steel 304 a prime candidate for a wide range of applications. Among different manufacturing techniques, electrical discharge machining (EDM) has shown high potential in processing stainless steel 304 in a controllable manner. This paper reports the results of an experimental investigation into the effect of the process parameters on the obtainable surface roughness and material removal rate of stainless steel 304, when slotted using wire EDM. A full factorial design of the experiment was followed when conducting experimental trials in which the effects of the different levels of the five process parameters; applied voltage, traverse feed, pulse-on time, pulse-off time, and current intensity were investigated. The geometry of the cut slots was characterized using the MATLAB image processing toolbox to detect the edge and precise width of the cut slot along its entire length to determine the material removal rate. In addition, the surface roughness of the side walls of the slots were characterized, and the roughness average was evaluated for the range of the process parameters being examined. The effect of the five process parameters on both responses were studied, and the results revealed that the material removal rate is significantly influenced by feed (p-value = 9.72 × 10−29), followed by current tension (p-value = 6.02 × 10−7), and voltage (p-value = 3.77 × 10−5), while the most significant parameters affecting the surface roughness are current tension (p-value = 1.89 × 10−7), followed by pulse-on time (1.602 × 10−5), and pulse-off time (0.0204). The developed regression models and associated prediction plots offer a reliable tool to predict the effect of the process parameters, and thus enable the optimizing of their effects on both responses; surface roughness and material removal rate. The results also reveal the trade-off between the effect of significant process parameters on the material removal rate and surface roughness. This points out the need for a robust multi-objective optimization technique to identify the process window for obtaining high quality surfaces while keeping the material removal rate as high as possible.

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Post-processing of additively manufactured metallic alloys – A review

Cited by 98 publications

References 244 publications

Recent Advances on Composition-Microstructure-Properties Relationships of Precipitation Hardening Stainless Steel

Recent Advances on Composition-Microstructure-Properties Relationships of Precipitation Hardening Stainless Steel

The Additive-Subtractive Process Chain - a Review

Experimental Investigation of Surface Roughness and Material Removal Rate in Wire EDM of Stainless Steel 304

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