Powder-based additive manufacturing - a review of types of defects, generation mechanisms, detection, property evaluation and metrology

Collins, Peter C.; Bond, Leonard J.; Taheri, Hossein; Bigelow, Timothy A.; Shoaib, Mohammad Rashid Bin Mohammad; Koester, Lucas W.

doi:10.1504/ijasmm.2017.10009247

Cited by 18 publications

(5 citation statements)

References 0 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The various types of microstructural features or defects, their generation mechanisms, their effect on bulk properties, and the capability of existing characterization methodologies for powder-based AM parts were considered by Collins et al [55], who pointed out the importance of their in-situ detection by non-destructive tests. Recently, Snow et al [56] found that these flaws in AM-produced material are an important defect that penalize fatigue resistance, by the application of machine learning approaches they distinguish different types by attending to geometry and size: gas porosity and keyhole pores, (~50 µm or less) relatively spherical, and lack of fusion pores with an irregular morphology, often much larger,.…”

Section: Classification and Identificationmentioning

confidence: 99%

Additive Manufacturing Processes in Selected Corrosion Resistant Materials: A State of Knowledge Review

et al. 2023

View full text Add to dashboard Cite

Additive manufacturing is an important and promising process of manufacturing due to its increasing demand in all industrial sectors, with special relevance in those related to metallic components since it permits the lightening of structures, producing complex geometries with a minimum waste of material. There are different techniques involved in additive manufacturing that must be carefully selected according to the chemical composition of the material and the final requirements. There is a large amount of research devoted to the technical development and the mechanical properties of the final components; however, not much attention has been paid yet to the corrosion behaviour in different service conditions. The aim of this paper is to deeply analyze the interaction between the chemical composition of different metallic alloys, the additive manufacturing processing, and their corrosion behaviour, determining the effects of the main microstructural features and defects associated with these specific processes, such as grain size, segregation, and porosity, among others. The corrosion resistance of the most-used systems obtained by additive manufacturing (AM) such as aluminum alloys, titanium alloys, and duplex stainless steels is analyzed to provide knowledge that can be a platform to create new ideas for materials manufacturing. Some conclusions and future guidelines for establishing good practices related to corrosion tests are proposed.

show abstract

Section: Classification and Identificationmentioning

confidence: 99%

Additive Manufacturing Processes in Selected Corrosion Resistant Materials: A State of Knowledge Review

et al. 2023

View full text Add to dashboard Cite

show abstract

“…Rapid solidification rates and anomalous gas content increase the pore concentration of metal alloys (Fredriksson and Svensson 1976). In addition, the gas concentration in each bubble contributes to the growth of pores due to the mass transfer imbalance between the two fluids present in the Marangoni current (Collins et al 2017).…”

Section: Porositymentioning

confidence: 99%

Defect and Distortion in Powder Bed Fusion of Metal Additive Manufacturing Parts

Maurya

Kumar

2022

AJSTD

View full text Add to dashboard Cite

One of the state-of-the-art technologies for metal fabrication is laser powder bed fusion, which includes the following printing techniques: selective laser melting, selective laser sintering, direct metal laser sintering, and electron beam melting. This work examines defect formation in laser powder bed fusion, predominately focusing on selective laser melting. It also explores recent research findings on defect formation and classification and analyzes various internal defects, such as porosity, lack of fusion, balling, and solidification cracking. The influence of process parameters on defect formation and the effect of defects on mechanical properties are analyzed. This review also discusses defect inspection technologies (melt pool, scan path, and slice monitoring), defect mitigation strategies (online detection, process parameters, and numerical simulation), and their applications in additive manufacturing, such as laser powder bed fusion. This review would aid manufacturers in determining the root cause of defect formation and developing inspection technologies and mitigation strategies.

show abstract

“…This ap-proach is inspired by the recycling pathway using laser-or electron-beam-based equipment with simplified control of the beam used just for melting scrap material into ingots [171][172][173], but it has the advantage of conducting essentially full recycling at the manufacturing site without any need for costly and hazardous transportation of powders to a specialized recycling site. Repairing and remanufacturing using additive manufacturing [143,[178][179][180][181][182]. This review also provides a brief overview of laser shock peening, one of the potential industrial post-processing routes allowing for reducing residual stresses in additively manufactured components and increasing their value as CRM-reducing and CRM-sparing manufacturing routes.…”

Section: Recycling Of Metal Powders For Additive Manufacturingmentioning

confidence: 99%

“…Further progress in solving CRM-related challenges belongs to the developing trends in AM and its deep integration with other processing modalities. Several AM-related possibilities to reduce and optimize the use of CRMs and CRM-based materials are discussed in this review: Use of hybrid manufacturing [ 138 , 146 , 174 ]; Production of multimaterial components [ 175 , 176 ]; Production of functionally graded materials (FGMs) [ 153 , 165 , 177 , 178 ]; Repairing and remanufacturing using additive manufacturing [ 143 , 178 , 179 , 180 , 181 , 182 ]. …”

Section: Modern and Future Trends In Additive Manufacturing Of Crmmentioning

confidence: 99%

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

et al. 2021

View full text Add to dashboard Cite

The term “critical raw materials” (CRMs) refers to various metals and nonmetals that are crucial to Europe’s economic progress. Modern technologies enabling effective use and recyclability of CRMs are in critical demand for the EU industries. The use of CRMs, especially in the fields of biomedicine, aerospace, electric vehicles, and energy applications, is almost irreplaceable. Additive manufacturing (also referred to as 3D printing) is one of the key enabling technologies in the field of manufacturing which underpins the Fourth Industrial Revolution. 3D printing not only suppresses waste but also provides an efficient buy-to-fly ratio and possesses the potential to entirely change supply and distribution chains, significantly reducing costs and revolutionizing all logistics. This review provides comprehensive new insights into CRM-containing materials processed by modern additive manufacturing techniques and outlines the potential for increasing the efficiency of CRMs utilization and reducing the dependence on CRMs through wider industrial incorporation of AM and specifics of powder bed AM methods making them prime candidates for such developments.

show abstract

Powder-based additive manufacturing - a review of types of defects, generation mechanisms, detection, property evaluation and metrology

Cited by 18 publications

References 0 publications

Additive Manufacturing Processes in Selected Corrosion Resistant Materials: A State of Knowledge Review

Additive Manufacturing Processes in Selected Corrosion Resistant Materials: A State of Knowledge Review

Defect and Distortion in Powder Bed Fusion of Metal Additive Manufacturing Parts

Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

Contact Info

Product

Resources

About