Process-Structure-Property Relationships in Additively Manufactured Metal Matrix Composites

Fereiduni, Eskandar; Elbestawi, M.A.

doi:10.1007/978-3-319-91713-9_4

Cited by 8 publications

(7 citation statements)

References 187 publications

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“…However, it is rather challenging to fabricate geometrically complex parts using these processes. Additive manufacturing (AM) is regarded as a major revolution in the manufacturing technology and competes with conventional manufacturing processes in many aspects, including, but not limited to, the design freedom, fabrication cost and time, accuracy and the part quality [15,16].…”

Section: Introductionmentioning

confidence: 99%

“…Incorporation of the guest powder particles (e.g., ceramic particles) into the host powder particles (usually metallic particles) leads to the production of composite powder feedstocks with different characteristics from the individual constituents. The particle size, particle size distribution, and distribution state of the guest powder particles are among these features which dictate the apparent density, flowability, and laser absorptivity of the composite powder [15,16]. The laser absorptivity influences the heat absorption, and the melt pool size [44,47,48], while the flowability and the apparent packing density of the powder play crucial roles in layer thickness (dimensional accuracy) and density of the final part [17,49,50,51,52].…”

Section: Introductionmentioning

confidence: 99%

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Characterization of Composite Powder Feedstock from Powder Bed Fusion Additive Manufacturing Perspective

2019

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This research aims at evaluating the characteristics of the 5 wt.% B4C/Ti-6Al-4V composite powder feedstock prepared by two different categories of mechanical mixing for powder bed fusion (PBF) additive manufacturing (AM) of metal matrix composites (MMCs). Microstructural features, particle size, size distribution, sphericity, conditioned bulk density and flow behavior of the developed powders were examined. The flowability of the regularly mixed powders was significantly lower than that of the Ti-6Al-4V powder. However, the flowability of the ball-milled systems was a significant function of the milling time. The decrease in the flowability of the 2 h ball-milled powder compared to the Ti-6Al-4V powder was attributed to the mechanical interlocking and the entangling caused by the B4C particles fully decorating the Ti-6Al-4V particles. Although the flattened/irregular shape of powder particles in the 6 h milled system acted to reduce the flowability, the overall surface area reduction led to higher flowability than that for the 2 h milling case. Regardless of the mixing method, incorporation of B4C particles into the system decreased the apparent density of the Ti-6Al-4V powder. The composite powder obtained by 2 h of ball milling was suggested as the best possible condition, meeting the requirements of PBF–AM processes.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Characterization of Composite Powder Feedstock from Powder Bed Fusion Additive Manufacturing Perspective

2019

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“…The absence of un-melted/partially melted powder particles in most of these pores proves that they are formed due to the limited flow of the molten material to fill the large voids within the powder bed [58]. The fraction of these large pores shows a descending trend by increasing the laser power, which can be attributed to the larger melt pool, lower melt viscosity, lower cooling rate and higher chance of the molten material to fill the pores (Figure 7(d)-(f)) [59][60][61]. That is why the large pores are almost eliminated at the laser power of 370 W in the fine powder system (Figure 7(f)).…”

Section: Densification Levelmentioning

confidence: 94%

Role of powder particle size on laser powder bed fusion processability of AlSi10mg alloy

Balbaa

Ghasemi

Fereiduni

et al. 2021

Additive Manufacturing

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Laser powder bed fusion (L-PBF) is one of the most promising additive manufacturing (AM) methods which provides an exceptional opportunity to improve the existing designs and move toward fabricating fine features and complex geometries with higher efficiencies. Considering the layer-wise nature of this technique, the possibility of fabricating fine features is tied to the ability to deposit thin powder layers in this process. Since the powder layer thickness is directly dictated by the powder particle size, finer powders are required to further enhance the ability of the L-PBF technique in manufacturing fine features and intricate geometries. Accordingly, this study aims at investigating the processability of fine AlSi10Mg powder (D50 = 9 µm) by using the L-PBF process. The densification level, surface quality and dimensional accuracy of the final parts are investigated in a wide range of process parameters and are compared to those manufactured by the commonly used AlSi10Mg powder (referred to as coarse powder with D50 = 40 µm).The underlying reasons behind the different processability of fine and coarse powders are explored from the density, surface quality, microhardness and dimensional accuracy viewpoints through analyzing the flowability, bed packing density and optical absorption of powders. Moreover, the process-microstructuremicrohardness relationship is assessed in detail for both fine and coarse powders. This study reinforces the idea that the utilization of fine powders in the range used in this study for L-PBF processing is rather challenging.

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“…This innovative process involves converting a computer-aided design (CAD) model into a physical object through a layer-by-layer building approach. Latterly, Dadkhah et al 19 , Mostafaei et al 20 and Fereiduni and Elbesawi 21 have conducted extensive reviews of the application of AM technology for manufacturing MMCs.…”

Section: Introductionmentioning

confidence: 99%

Fabrication and tunable reinforcement of net-shaped aluminum matrix composite parts via 3D printing

Seleznev,

Roy-Mayhew,

Faust

2023

Sci Rep

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Advanced materials, such as metal matrix composites (MMCs), are important for innovation, national security, and addressing climate change. MMCs are used in military, aerospace, and automotive applications because of their exceptional mechanical and thermal properties, however adoption has been slow due to costly and onerous manufacturing processes. A new process using fused filament fabrication 3D printing has been developed to make net shape MMCs without tooling or machining. The process involves printing an alumina preform and then using pressure-less infiltration with a molten aluminum alloy to form the composite. Arbitrary shapes can be formed in this process—a brake lever and a flange are demonstrated—and the properties can be tuned by varying the ceramic infill geometric pattern and ceramic loading. By using 35 vol% continuous fiber reinforcement over 800 MPa strength and 140 GPa modulus are achieved for the aluminum composite, 3.4 × and 2 × the matrix aluminum properties.

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Process-Structure-Property Relationships in Additively Manufactured Metal Matrix Composites

Cited by 8 publications

References 187 publications

Characterization of Composite Powder Feedstock from Powder Bed Fusion Additive Manufacturing Perspective

Characterization of Composite Powder Feedstock from Powder Bed Fusion Additive Manufacturing Perspective

Role of powder particle size on laser powder bed fusion processability of AlSi10mg alloy

Fabrication and tunable reinforcement of net-shaped aluminum matrix composite parts via 3D printing

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