Recent progress on microstructure manipulation of aluminium alloys manufactured via laser powder bed fusion

Xiao, Zhen; Yu, Wenhui; Fu, Hongxun; Deng, Yaoji; Wu, Yongling

doi:10.1080/17452759.2022.2125880

Cited by 23 publications

(4 citation statements)

References 133 publications

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“…Powder bed fusion is an additive manufacturing technique, which has enabled the fabrication of geometrically complex metallic structures. 1,2 The basis of this technology is the selective consolidation of thin layers of metallic powders via processing with a focused high energy laser beam based on a computer aided design model. Among these technologies, selective laser melting (SLM) is arguably more suited to small feature resolution.…”

Section: Introductionmentioning

confidence: 99%

Chemical etching of Ti‐6Al‐4V biomaterials fabricated by selective laser melting enhances mesenchymal stromal cell mineralization

O'Keeffe,

Kotlarz,

Gonçalves

et al. 2024

J Biomedical Materials Res

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Porous titanium scaffolds fabricated by powder bed fusion additive manufacturing techniques have been widely adopted for orthopedic and bone tissue engineering applications. Despite the many advantages of this approach, topological defects inherited from the fabrication process are well understood to negatively affect mechanical properties and pose a high risk if dislodged after implantation. Consequently, there is a need for further post‐process surface cleaning. Traditional techniques such as grinding or polishing are not suited to lattice structures, due to lack of a line of sight to internal features. Chemical etching is a promising alternative; however, it remains unclear if changes to surface properties associated with such protocols will influence how cells respond to the material surface. In this study, we explored the response of bone marrow derived mesenchymal stem/stromal cells (MSCs) to Ti‐6Al‐4V whose surface was exposed to different durations of chemical etching. Cell morphology was influenced by local topological features inherited from the SLM fabrication process. On the as‐built surface, topological nonhomogeneities such as partially adhered powder drove a stretched anisotropic cellular morphology, with large areas of the cell suspended across the nonhomogeneous powder interface. As the etching process was continued, surface defects were gradually removed, and cell morphology appeared more isotropic and was suggestive of MSC differentiation along an osteoblastic‐lineage. This was accompanied by more extensive mineralization, indicative of progression along an osteogenic pathway. These findings point to the benefit of post‐process chemical etching of additively manufactured Ti‐6Al‐4V biomaterials targeting orthopedic applications.

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Section: Introductionmentioning

confidence: 99%

Chemical etching of Ti‐6Al‐4V biomaterials fabricated by selective laser melting enhances mesenchymal stromal cell mineralization

O'Keeffe,

Kotlarz,

Gonçalves

et al. 2024

J Biomedical Materials Res

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“…Laser powder bed fusion (LPBF) is a method of manufacturing that involves the use of lasers to fuse powdered materials together. It is commonly utilized because of its exceptional capacity for mechanical shaping in industry [ 1 , 2 , 3 , 4 , 5 , 6 ]. However, the quality of the built pieces is mostly affected by the thermal history that the material undergoes during the manufacturing process, while the temperature history can be influenced by many factors, such as process parameters, material properties, scan strategies, and so on [ 7 , 8 , 9 ].…”

Section: Introductionmentioning

confidence: 99%

Model-Based Sensitivity Analysis of the Temperature in Laser Powder Bed Fusion

Yang,

Zhang,

et al. 2024

Materials

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To quantitatively evaluate the effect of the process parameters and the material properties on the temperature in laser powder bed fusion (LPBF), this paper proposed a sensitivity analysis of the temperature based on the validated prediction model. First, three different heat source modes—point heat source, Gaussian surface heat source, and Gaussian body heat source—were introduced. Then, a case study of Ti6Al4V is conducted to determine the suitable range of heat source density for the three different heat source models. Based on this, the effects of laser processing parameters and material thermophysical parameters on the temperature field and molten pool size are quantitatively discussed based on the Gaussian surface heat source. The results indicate that the Gaussian surface heat source and the Gaussian body heat source offer higher prediction accuracy for molten pool width compared to the point heat source under similar processing parameters. When the laser energy density is between 40 and 70 J/mm3, the prediction accuracy of the Gaussian surface heat source and the body heat source is similar, and the average prediction errors are 4.427% and 2.613%, respectively. When the laser energy density is between 70 and 90 J/mm3, the prediction accuracy of the Gaussian body heat source is superior to that of the Gaussian surface heat source. Among the influencing factors, laser power exerts the greatest influence on the temperature field and molten pool size, followed by scanning speed. In particular, laser power and scan speed contribute 38.9% and 23.5% to the width of the molten pool, 39.1% and 19.6% to the depth of the molten pool, and 38.9% and 21.5% to the maximum temperature, respectively.

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“…However, the suggestion of the mechanism relating to remelting seems to be still prevailing as described in a recent review on the progress of aluminum‐alloy LPBF [ 24 ] and in a review specifically on LPBF of Sc‐containing aluminum alloys. [ 25 ] Recently, Ekubaru et al [ 23 ] demonstrated that controlling hatch spacing can control the amount of equiaxed grains and thus can control the strength of the alloy through grain‐boundary strengthening.…”

Section: Introductionmentioning

confidence: 99%

On the Mechanism of Formation of Bimodal Grain Structure in Al–4.5Mg–0.7Sc–0.3Zr Alloy Processed by Laser Powder Bed Fusion

Chernyshova¹,

Guraya

Martínez-Amesti

et al. 2023

Adv Eng Mater

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Scalmalloy is an Al–Mg alloy with additions of Sc and Zr originally developed as a high‐strength aluminum alloy with σ0.2 ≥ 450 MPa for aerospace industry. It is now well understood that the alloy is amendable for processing by laser powder bed fusion (LPBF). However, the mechanism of formation of the equiaxed‐columnar bimodal grain structure during LPBF is not ascertained yet, fully. Herein, this gap is addressed with special focus on the distributions of critical elements such as Sc and various particles that form during LBPF. It is found that strong and weak segregation of Mg and Sc, respectively, occurs in the final solidification areas of the fine‐ and equiaxed‐grain regions. The coarser and columnar grain regions show weak segregation of Mg and no Sc segregation. A priori knowledge on the Al–Sc eutectic reaction, its dependence on cooling rates, and the well‐known thermal and solidification conditions related to the track location during LPBF is used to ascertain the mechanism of formation of the bimodal grain structure. The mechanism suggested is substantiated by the location‐dependent elemental distributions and the various particles that are observed.

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Recent progress on microstructure manipulation of aluminium alloys manufactured via laser powder bed fusion

Cited by 23 publications

References 133 publications

Chemical etching of Ti‐6Al‐4V biomaterials fabricated by selective laser melting enhances mesenchymal stromal cell mineralization

Chemical etching of Ti‐6Al‐4V biomaterials fabricated by selective laser melting enhances mesenchymal stromal cell mineralization

Model-Based Sensitivity Analysis of the Temperature in Laser Powder Bed Fusion

On the Mechanism of Formation of Bimodal Grain Structure in Al–4.5Mg–0.7Sc–0.3Zr Alloy Processed by Laser Powder Bed Fusion

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