Additive manufacturing of a precious bulk metallic glass

Sohrabi, Navid; Jhabvala, Jamasp; Kurtuldu, Güven; Frison, Ruggero; Parrilli, Annapaola; Stoica, M.; Neels, Antonia; Löffler, Jörg F.; Logé, Roland E.

doi:10.1016/j.apmt.2021.101080

Cited by 23 publications

(33 citation statements)

References 88 publications

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“…Although the XRD pattern of the AB sample (see Figure 3) indicates an amorphous structure, nanocrystals were formed in HAZs due to the local thermal cycles induced in these regions by the overlapping and adjacent track deposition. The conventional XRD method is not sensitive enough to detect low volume fractions of crystallization, as already noticed in references [8,12,40,60].…”

Section: Discussionmentioning

confidence: 98%

“…Recent progress in laser powder-bed fusion (LPBF), the most widely used additive manufacturing (AM) technique for metals, has led to a strong interest in the manufacturing of bulk metallic glass (BMGs) [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15], since high local cooling rates induced by the LPBF process match the requirements for manufacturing BMGs with substantial dimensions and complex shapes [8]. This challenge generated a lot of enthusiasm due to the exceptional mechanical properties of BMGs, which make them possible candidates in a number of industrial fields, such as micro-mechanics, medicine, aerospace, and automotives.…”

Section: Introductionmentioning

confidence: 99%

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Fatigue Performance of an Additively Manufactured Zr-Based Bulk Metallic Glass and the Effect of Post-Processing

Sohrabi

Nasab

Rouxel

et al. 2021

Metals

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Fatigue is the most common cause of failure of mechanical parts in engineering applications. In the current work, we investigate the fatigue life of a bulk metallic (BMG) glass fabricated via additive manufacturing. Specimens fabricated via laser powder-bed fusion (LPBF) are shown to have a fatigue ratio of 0.20 (fatigue limit of 175 MPa) in a three-point bending fatigue test. Three strategies for improving the fatigue behavior were tested, namely (1) relaxation heat treatment, giving a slight fatigue life improvement at high loading conditions (≥250 MPa), (2) laser shock peening, and (3) changing the build orientation, the latter two of which yielded no significant effects. It was found that the presence of lack of fusion (LoF) had the preponderant effect on fatigue resistance of the specimens manufactured. LoF was observed to be a source of stress localization and initiation of cracks. The fatigue life in BMGs fabricated by LPBF is thus primarily influenced by powder quality and process-induced defects, which cannot be removed by the post-treatments carried out in this study. It is believed that a slight increase in laser power, either in the near-surface regions or in the core of the specimens, could improve the fatigue behavior despite the associated (detrimental) increase of crystallized fraction.

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Section: Discussionmentioning

confidence: 98%

Section: Introductionmentioning

confidence: 99%

Fatigue Performance of an Additively Manufactured Zr-Based Bulk Metallic Glass and the Effect of Post-Processing

Sohrabi

Nasab

Rouxel

et al. 2021

Metals

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“…Although, BMG produced using SLM showed high hardness, wear resistance, compressive strength, and flexural strength, their properties was mostly inferior or in some cases comparable to their as-cast counterpart [405,417,423]. In addition, the SLM-fabricated BMGs showed low plastic strain even lower than their as-cast counterpart.…”

Section: Mechanical Properties Of Powder Bed Fusion Additive Manufactured Bmgsmentioning

confidence: 92%

“…The first attempt to used SLM to fabricate fully amorphous BMG components under the appropriate conditions was carried out by Pauly et al [388] in 2013. Since then, several other BMGs based on Fe [388][389][390][391][392][393][394][395][396], Al [397][398][399][400], Zr [401][402][403][404][405][406][407][408][409][410][411][412][413][414], Cu [415,416], Pd [417], and Ti [418] have been fabricated using the laser PBF process. A sample made of Fe-based BMGs as large as 45 mm in diameter and 20 mm in length was fabricated by Wang et al [419].…”

Section: Bulk Metallic Glasses (Bmgs)mentioning

confidence: 99%

“…A nearly fully amorphous structure of Cu-based BMG with nanometer-size crystalline phases was achieved at a laser energy density of 25 J/mm 3 . However, Sohrabi et al [417] found that low volumetric energy density values (<3 J/mm 3 ) led to higher porosity in SLM-built Pd-based BMGs, and much larger values (>6 J/mm 3 ) resulted in curved and irregular surfaces due to heat accumulation, which reduces the accuracy of the part. Therefore, optimization of parameters is required to balance between porosity and amorphization.…”

Section: Microstructural Characterization and Part Quality Of Powder Bed Fusion Additive Manufactured Bmgsmentioning

confidence: 99%

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Review of Powder Bed Fusion Additive Manufacturing for Metals

Ladani

Sadeghilaridjani

2021

Metals

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Additive manufacturing (AM) as a disruptive technology has received much attention in recent years. In practice, however, much effort is focused on the AM of polymers. It is comparatively more expensive and more challenging to additively manufacture metallic parts due to their high temperature, the cost of producing powders, and capital outlays for metal additive manufacturing equipment. The main technology currently used by numerous companies in the aerospace and biomedical sectors to fabricate metallic parts is powder bed technology, in which either electron or laser beams are used to melt and fuse the powder particles line by line to make a three-dimensional part. Since this technology is new and also sought by manufacturers, many scientific questions have arisen that need to be answered. This manuscript gives an introduction to the technology and common materials and applications. Furthermore, the microstructure and quality of parts made using powder bed technology for several materials that are commonly fabricated using this technology are reviewed and the effects of several process parameters investigated in the literature are examined. New advances in fabricating highly conductive metals such as copper and aluminum are discussed and potential for future improvements is explored.

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High‐Entropy Alloy‐Induced Metallic Glass Transformation: Challenges Posed by in situ Alloying via Additive Manufacturing

et al. 2022

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In situ alloying and fabricating glassy structures through a layer‐by‐layer fashion approach are challenging but have high potential to develop novel‐graded materials. For the first time, this cost‐effective approach is applied to additive manufacturing (AM) of a Zr‐based bulk metallic glass (BMG) from high‐entropy alloys (HEAs). A newly developed composition of Zr40Al20Cu20Ti20 is fabricated through laser powder bed fusion (LPBF). Process parameters are optimized within a wide range of laser power (50–200 W) as well as scanning speed (50–800 mm s−1). In all printed samples, microscopic and compositional examinations reveal no glass formation, but very fine grains and CuTi and AlTi nanocrystals. Some glassy transitions at the interfaces may be encouraged to occur with proper melting and mixing. However, the main reason for not obtaining a glassy matrix is the substantial proportion of unmelted Zr raw powder throughout the structure as spherical particles. Consequently, glass formation can be hindered by a considerable amount of compositional deviation. During LPBF, in situ alloying poses significant challenges to developing BMGs. Hence, the various stages of the process, including raw material specifications, laser settings, and process parameters, should be investigated further.

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Additive manufacturing of a precious bulk metallic glass

Cited by 23 publications

References 88 publications

Fatigue Performance of an Additively Manufactured Zr-Based Bulk Metallic Glass and the Effect of Post-Processing

Fatigue Performance of an Additively Manufactured Zr-Based Bulk Metallic Glass and the Effect of Post-Processing

Review of Powder Bed Fusion Additive Manufacturing for Metals

High‐Entropy Alloy‐Induced Metallic Glass Transformation: Challenges Posed by in situ Alloying via Additive Manufacturing

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