Powder bed fusion–laser melting (PBF–LM) process: latest review of materials, process parameter optimization, application, and up-to-date innovative technologies

Ali, Hazrat; Sabyrov, Nurbol; Shehab, Essam

doi:10.1007/s40964-022-00311-9

Cited by 15 publications

(3 citation statements)

References 151 publications

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“…Moreover, many AM metal machine producers sell machines without providing information on alloy PBF-LB processing parameters, even for the popular alloys mentioned above. Consequently, procedures that aid in optimizing the PBF-LB process parameters and reducing sample size and batches should continue to be explored and shared with a wider audience [10][11][12]. This is particularly crucial in an era characterized by shortened or interrupted supply chains, escalating energy costs, and the growing necessity to utilize recycled materials, even in the production of high-end and advanced products.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Properties of Ti Grade 2 Manufactured Using Laser Beam Powder Bed Fusion (PBF-LB) with Checkerboard Laser Scanning and In Situ Oxygen Strengthening

Wysocki,

Chmielewska-Wysocka,

Maj

et al. 2024

Crystals

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Additive manufacturing (AM) technologies have advanced from rapid prototyping to becoming viable manufacturing solutions, offering users both design flexibility and mechanical properties that meet ISO/ASTM standards. Powder bed fusion using a laser beam (PBF-LB), a popular additive manufacturing process (aka 3D printing), is used for the cost-effective production of high-quality products for the medical, aviation, and automotive industries. Despite the growing variety of metallic powder materials available for the PBF-LB process, there is still a need for new materials and procedures to optimize the processing parameters before implementing them into the production stage. In this study, we explored the use of a checkerboard scanning strategy to create samples of various sizes (ranging from 130 mm3 to 8000 mm3 using parameters developed for a small 125 mm3 piece). During the PBF-LB process, all samples were fabricated using Ti grade 2 and were in situ alloyed with a precisely controlled amount of oxygen (0.1–0.4% vol.) to enhance their mechanical properties using a solid solution strengthening mechanism. The samples were fabricated in three sets: I. Different sizes and orientations, II. Different scanning strategies, and III. Rods for high-cycle fatigue (HCF). For the tensile tests, micro samples were cut using WEDM, while for the HCF tests, samples were machined to eliminate the influence of surface roughness on their mechanical performance. The amount of oxygen in the fabricated samples was at least 50% higher than in raw Ti grade 2 powder. The O2-enriched Ti produced in the PBF-LB process exhibited a tensile strength ranging from 399 ± 25 MPa to 752 ± 14 MPa, with outcomes varying based on the size of the object and the laser scanning strategy employed. The fatigue strength of PBF-LB fabricated Ti was 386 MPa, whereas the reference Ti grade 2 rod samples exhibited a fatigue strength of 312 MPa. Our study revealed that PBF-LB parameters optimized for small samples could be adapted to fabricate larger samples using checkerboard (“island”) scanning strategies. However, some additional process parameter changes are needed to reduce porosity.

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Section: Introductionmentioning

confidence: 99%

Mechanical Properties of Ti Grade 2 Manufactured Using Laser Beam Powder Bed Fusion (PBF-LB) with Checkerboard Laser Scanning and In Situ Oxygen Strengthening

Wysocki,

Chmielewska-Wysocka,

Maj

et al. 2024

Crystals

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“…Different metal additive manufacturing processes have been developed, for example, directed energy deposition (DED), wire deposition using laser or electron beam sources, binder jet printing, electron beam melting (EBM), laser powder bed fusion (LPBF), friction stir additive manufacturing, and new technologies combining some of these techniques. Laser powder bed fusion is used when parts with high geometrical complexity and density near 100% are required [ 5 ]. Parts are made in LPBF by creating solid material in patterned layers [ 6 ].…”

Section: Introductionmentioning

confidence: 99%

Powder Spreading Mechanism in Laser Powder Bed Fusion Additive Manufacturing: Experiments and Computational Approach Using Discrete Element Method

Habiba

Hebert

2023

Materials

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Laser powder bed fusion (LPBF) additive manufacturing (AM) has been adopted by various industries as a novel manufacturing technology. Powder spreading is a crucial part of the LPBF AM process that defines the quality of the fabricated objects. In this study, the impacts of various input parameters on the spread of powder density and particle distribution during the powder spreading process are investigated using the DEM (discrete element method) simulation tool. The DEM simulations extend over several powder layers and are used to analyze the powder particle packing density variation in different layers and at different points along the longitudinal spreading direction. Additionally, this research covers experimental measurements of the density of the powder packing and the powder particle size distribution on the construction plate.

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“…As an advanced near-net shape manufacturing technology, laser powder bed fusion (L-PBF) has shown an efficient capability to produce different metals in complex shapes with high geometrical accuracy [ 6 ]. This could significantly reduce the required finishing, machining, and forming processes needed after the traditional processing of brittle materials such as TiAl.…”

Section: Introductionmentioning

confidence: 99%

Influence of Combined Heat Treatment and Hot Isostatic Pressure (HT-HIP) on Titanium Aluminide Processed by L-PBF

Soliman

Pineault²,

Elbestawi

2023

Materials

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Postprocessing is essential for improving titanium aluminide (TiAl) microstructure and part quality after using the laser powder bed fusion (L-PBF) method. It has been reported that Ti-48Al-2Cr-2Nb (%at) processed by L-PBF has internal defects and low fracture toughness. Microstructure control by heat treatment (HT) showed a significant improvement in the ductility of the material. Alternatively, hot isostatic pressing (HIPing) could be applied to reduce the residual stresses and internal defects formed during the L-PBF. Combining the benefits of these two subsequent processes into a single predetermined process is appealing for Ti-48Al-2Cr-2Nb (%at) to minimize cost. This work presents a novel strategy to postprocess L-PBF TiAl by applying combined heat treatment and hot isostatic pressing in one process, namely HT-HIP. The process includes three cycles with different conditions (i.e., temperature, time, and pressure). These conditions were determined to achieve improved part quality and microstructure. The results show that the tensile residual stresses decreased from a peak of 249 MPa in the as-built sample to compressive stresses that peaked at −90 MPa after the HT-HIP process. The number and size of internal defects could be greatly reduced. The defects were transformed into a regular spherical shape, which is good in terms of fatigue strength. Additionally, a duplex microstructure with lamellar α2/γ colonies could be introduced for better ductility. Different levels of duplex microstructure could be achieved along with the process cycles. The grain structure using EBSD analysis showed refined equiaxed grains, which demonstrate better strength after the HT-HIP process. Twinning boundaries were also observed in the HT-HIP sample. The grain orientation tendency to the build direction significantly reduced after the HT-HIP process. The nanoindentation test was applied to evaluate the nanohardness of the as-built and HT-HIP samples. It could be demonstrated that the nanohardness is dependent on the formed phases and lamellar density inside the grains. The mean hardness value was 8.19 GPa for the as-built sample, while it was 5.48 GPa for the HT-HIP sample.

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Powder bed fusion–laser melting (PBF–LM) process: latest review of materials, process parameter optimization, application, and up-to-date innovative technologies

Cited by 15 publications

References 151 publications

Mechanical Properties of Ti Grade 2 Manufactured Using Laser Beam Powder Bed Fusion (PBF-LB) with Checkerboard Laser Scanning and In Situ Oxygen Strengthening

Mechanical Properties of Ti Grade 2 Manufactured Using Laser Beam Powder Bed Fusion (PBF-LB) with Checkerboard Laser Scanning and In Situ Oxygen Strengthening

Powder Spreading Mechanism in Laser Powder Bed Fusion Additive Manufacturing: Experiments and Computational Approach Using Discrete Element Method

Influence of Combined Heat Treatment and Hot Isostatic Pressure (HT-HIP) on Titanium Aluminide Processed by L-PBF

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