Powder Bed Fusion of nickel-based superalloys: A review

Sanchez, Salomé; Smith, Pauline; Xu, Zhaowen; Gaspard, Gabriele; Hyde, Christopher; Wits, Wessel W.; Ashcroft, Ian; Chen, Hao; Clare, Adam T.

doi:10.1016/j.ijmachtools.2021.103729

Cited by 310 publications

(66 citation statements)

References 311 publications

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“…For this reason, the microstructure obtained with the L-PBF technique differs from the conventional manufacturing techniques (i.e., rolling, casting, or forging), During the L-PBF process, non-equilibrium solidification occurs due to the rapid cooling. Furthermore, preferential grain growth along with the heterogeneous structure can take place due to the complex heat transfer and large temperature gradients formed in a melt pool [ 17 , 18 ]. Additionally, some microstructure and materials-related problems can be observed in the L-PBF technique.…”

Section: Solidification Microstructure Evolution Within Pbf-lbmentioning

confidence: 99%

Digitisation of metal AM for part microstructure and property control

et al. 2022

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Metal additive manufacturing, which uses a layer-by-layer approach to fabricate parts, has many potential advantages over conventional techniques, including the ability to produced complex geometries, fast new design part production, personalised production, have lower cost and produce less material waste. While these advantages make AM an attractive option for industry, determining process parameters which result in specific properties, such as the level of porosity and tensile strength, can be a long and costly endeavour. In this review, the state-of-the-art in the control of part properties in AM is examined, including the effect of microstructure on part properties. The simulation of microstructure formation via numerical simulation and machine learning is examined which can provide process quality control and has the potential to aid in rapid process optimisation via closed loop control. In-situ monitoring of the AM process, is also discussed as a route to enable first time right production in the AM process, along with the hybrid approach of AM fabrication with post-processing steps such as shock peening, heat treatment and rolling. At the end of the paper, an outlook is presented with a view towards potential avenues for further research required in the field of metal AM.

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Section: Solidification Microstructure Evolution Within Pbf-lbmentioning

confidence: 99%

Digitisation of metal AM for part microstructure and property control

et al. 2022

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“…However, accurate results could not be achieved using this machine due to the uneven flow of argon gas and lack-of-fusion defect related to the oxide phase that occurred during the process under a high oxygen environment. Inert gases like argon have a vital role to reduce powder oxidation in the PBF process [30], [31]. The quality and mechanical properties of the product fabricated by the PBF technology are significantly influenced by the residual oxygen content, gas atmosphere, and the gas flow inside the build chamber [32].…”

Section: Techology and Materialsmentioning

confidence: 99%

Direct Metal Laser Sintering of Precious Metals for Jewelry Applications: Process Parameter Selection and Microstructure Analysis

Korium

Roozbahani²,

Alizadeh

et al. 2021

IEEE Access

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Direct Metal Laser Sintering (DMLS) is an advanced additive manufacturing (AM) technique for the 3D printing of metals. This technology is also beneficial in the jewelry industry, where precious metals are used, and the design and price are determinative factors. In this paper, the metal 3D printing process for jewelry production is discussed. Four rings made of gold, silver, titanium, and stainless-steel 316L have been designed and fabricated by AM machine based on the DMLS technique. Proper geometry and parameters for rings and support structure were determined. Results showed that a reduced amount of powder was required for 3D printing of metal rings using a locally developed AM machine. Besides, appropriate geometry and parameters for a jewelry box with a complex design have been specified to be fabricated from stainless steel 316L by the same AM machine. The quality of the final produced parts using DMLS technology was not demonstrated inferior compared to the quality of parts built by conventional manufacturing methods. Furthermore, utilizing an electron microscope the microstructures of the fabricated parts were obtained and analyzed in detail before and after polishing on the polisher machine. Results revealed that the maximum homogeneous surface was obtained for the gold and titanium samples, while the surface of the samples of stainless steel and silver had internal cavities, pores, and other defects. Also, it was concluded that usage of gold and silver for the manufacturing of jewelry product that does not experience heavy loads is quite justified.INDEX TERMS Additive Manufacturing (AM), Direct Metal Laser Sintering (DMLS), microstructure analysis, jewelry design, precious metals, 3D printing.

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“…To measure porosity in an LPBF part, there are three common approaches-(i) microscopy imaging (typically optical microscopy, OM), (ii) l-computed tomography (l-CT) and (iii) the Archimedes method. The OM approach is the simplest method for providing detailed porosity information, but it is Reproduced with permission from [44] (Copyright 2021, Elsevier).…”

Section: Introductionmentioning

confidence: 99%

“…Thus, this review differs from other similar articles such as [29][30][31]. Additionally, there are also other reviews that cover various aspects of these LPBF alloys such as [32][33][34][35][36][37][38][39][40][41][42][43] for Ti-6Al-4 V, [32,33,[44][45][46][47] for Inconel 718, [32-37, 48, 49] for AISI 316L and [33,[50][51][52][53][54][55][56] for AlSi10Mg.…”

Section: Introductionmentioning

confidence: 99%

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A critical review on the effects of process-induced porosity on the mechanical properties of alloys fabricated by laser powder bed fusion

et al. 2022

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Laser powder bed fusion (LPBF) is an emerging additive manufacturing technique that is currently adopted by a number of industries for its ability to directly fabricate complex near-net-shaped components with minimal material wastage. Two major limitations of LPBF, however, are that the process inherently produces components containing some amount of porosity and that fabricated components tend to suffer from poor repeatability. While recent advances have allowed the porosity level to be reduced to a minimum, consistent porosity-free fabrication remains elusive. Therefore, it is important to understand how porosity affects mechanical properties in alloys fabricated this way in order to inform the safe design and application of components. To this aim, this article will review recent literature on the effects of porosity on tensile properties, fatigue life, impact and fracture toughness, creep response, and wear behavior. As the number of alloys that can be fabricated by this technology continues to grow, this overview will mainly focus on four alloys that are commonly fabricated by LPBF—Ti-6Al-4 V, Inconel 718, AISI 316L, and AlSi10Mg.

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Powder Bed Fusion of nickel-based superalloys: A review

Cited by 310 publications

References 311 publications

Digitisation of metal AM for part microstructure and property control

Digitisation of metal AM for part microstructure and property control

Direct Metal Laser Sintering of Precious Metals for Jewelry Applications: Process Parameter Selection and Microstructure Analysis

A critical review on the effects of process-induced porosity on the mechanical properties of alloys fabricated by laser powder bed fusion

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