Additive manufacturing (AM), where a part is built layer-by-layer, is a promising approach for creating near-net shapes and is challenging the dominance of conventional manufacturing processes for products with high complexity and greater material efficiency 1 . However, achieving good mechanical properties in the as-produced part, given the variation in solidification conditions including the control of defects in AM, is challenging. In particular there are limited opportunities for post processing to further control the microstructure/properties. Therefore, further metallurgical research on materials for AM is required to accelerate the maturity of AM technology for structural components. 3D-printed titanium alloys have been used in numerous applications, including the biomedical and aerospace industries. However, the 3D-printing of many conventional titanium alloys usually results in a microstructure comprised of coarse columnar grains, which often leads to undesirable anisotropic mechanical properties. In contrast to other common engineering alloys, such as aluminium, there is no commercial grain refiner, containing potent inoculants that can survive in liquid Ti, able to control microstructure effectively. To address this challenge, we have developed a novel technique for AM by using Ti-Cu alloys with a high constitutional supercooling capacity that overrides the negative effect of a high thermal gradient in the melt pool during AM. Through this approach, it is shown that an as-printed Ti-Cu alloy specimen is comprised of fully equiaxed, fine grained microstructure without any special process control or additional subsequent treatment. The new AM Ti-Cu alloys also display promising mechanical properties, compared to conventional alloys under similar processing conditions, due to the formation of an ultrafine eutectoid microstructure by taking full advantage of the high cooling rates and multiple thermal cycles in the AM process. We anticipate that this approach will be equally applicable to other eutectoid forming alloy systems. MainMetal based 3D printing or additive manufacturing (AM) is enabling mass customization of manufactured parts. The intrinsic high cooling rates and high thermal gradient in the metal AM process often leads to a very fine microstructure and a tendency towards almost exclusively columnar grains particularly in Ti-based alloys 1 . Such columnar grains in AM Ti components can cause anisotropic mechanical properties and hence are not desirable 2 . Numerous attempts to optimise the processing parameters of AM have shown that it is extremely difficult to alter the conditions such that equiaxed growth of prior β-Ti grains is promoted 3 . According to the Interdependence Theory 4 , the key factors controlling grain Affiliations
Additive manufacturing (AM) of metals, also known as metal 3D printing, typically leads to the formation of columnar grain structures along the build direction in most as-built metals and alloys. These long columnar grains can cause property anisotropy, which is usually detrimental to component qualification or targeted applications. Here, without changing alloy chemistry, we demonstrate an AM solidification-control solution to printing metallic alloys with an equiaxed grain structure and improved mechanical properties. Using the titanium alloy Ti-6Al-4V as a model alloy, we employ high-intensity ultrasound to achieve full transition from columnar grains to fine (~100 µm) equiaxed grains in AM Ti-6Al-4V samples by laser powder deposition. This results in a 12% improvement in both the yield stress and tensile strength compared with the conventional AM columnar Ti-6Al-4V. We further demonstrate the generality of our technique by achieving similar grain structure control results in the nickel-based superalloy Inconel 625, and expect that this method may be applicable to other metallic materials that exhibit columnar grain structures during AM.
Metal additive manufacturing (AM) is an innovative manufacturing technique, which builds parts incrementally layer by layer. Thus, metal AM has inherent advantages in part complexity, time, and waste saving. However, due to its complex thermal cycle and rapid solidification during processing, the alloys well suit and commercially used for metal AM today are limited. Therefore, it is important to understand the alloying strategy and current progress with materials performance to consider alloy development for metal AM. This review presents the current range of alloys available for metal AM, including titanium, steel, nickel, aluminum, less common alloys (including Mg alloys, metal matrix composites alloys, and low melting point alloys), and compositionally complex alloys (including bulk metallic glasses and high entropy alloys) with a focus on the relationship between compositions, processing, microstructures, and properties of each alloy system. In addition, some promising alloy systems for metal AM are highlighted. Approaches for designing and optimizing new materials for metal AM have been summarized.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.
hi@scite.ai
10624 S. Eastern Ave., Ste. A-614
Henderson, NV 89052, USA
Copyright © 2024 scite LLC. All rights reserved.
Made with 💙 for researchers
Part of the Research Solutions Family.