Additive manufacturing of metal-based functionally graded materials: overview, recent advancements and challenges

Sanjeeviprakash, K.; Kannan, A. Rajesh; Shanmugam, N. Siva

doi:10.1007/s40430-023-04174-1

Cited by 12 publications

(1 citation statement)

References 218 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The fabrication of FGMs using FGAM, particularly with stainless steel and Inconel alloys, has garnered significant attention due to their potential applications in high-value industries. These alloys have exceptional mechanical and chemical properties, such as resilience in high-temperature hazard environments, corrosion resistance, and superior strength [14]. Generally, to evaluate the quality and integrity of deposited layers, researchers have assessed the correlation between the microstructure and measured mechanical properties [15,16].…”

Section: Introductionmentioning

confidence: 99%

A Study on Metallographic and Machining Characteristics of Functionally Graded Material Produced by Directed Energy Deposition

Noh,

Jeon,

Lee

2023

Crystals

View full text Add to dashboard Cite

Directed energy deposition (DED) stands as a key process in metal additive manufacturing (AM) and offers the unique capability of creating functionally graded materials (FGMs). FGMs have garnered significant interest in high-value industries by advantages such as performance optimization, reducing material defects, and resolving joining issues. However, post-processing remains a crucial step, indicating a need for further research to understand the machinability of FGMs. This paper focuses on the characteristics analysis of fabricating and machining an FGM based on stainless steel 316L (SAE 316L) and Inconel 718. The FGM was fabricated by starting with SAE 316L at 100 wt.% and adjusting the composition ratio by incrementally increasing Inconel 718 by 20 wt.% while simultaneously decreasing SAE 316L. Following the FGM fabrication, microstructure and mechanical properties were comprehensively analyzed by hardness testing, optical microstructure measurements, energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). To investigate the post-processing aspects, end-milling experiments were conducted using two distinct milling methods (upward and downward milling) and machining paths (from SAE 316L towards Inconel 718, and vice versa). The mean cutting force peaked at 148.4 N in upward milling and dipped to 70.5 N in downward milling, and tool wear measurements further provided insights into the optimal milling direction when working with an FGM of SAE 316L and Inconel 718.

show abstract

Section: Introductionmentioning

confidence: 99%

A Study on Metallographic and Machining Characteristics of Functionally Graded Material Produced by Directed Energy Deposition

Noh,

Jeon,

Lee

2023

Crystals

View full text Add to dashboard Cite

show abstract

Microstructural Control of a Multi‐Phase PH Steel Printed with Laser Powder Bed Fusion

Fields,

Amiri,

Lim

et al. 2024

Adv Materials Technologies

View full text Add to dashboard Cite

The established approach to materials design for additive manufacturing (AM) consists of attempting to reproduce the uniform structures and properties of conventionally processed materials. While this certainly helped facilitate material certification and the rapid introduction of AM technologies in several industries, the opportunity to exploit unique features of specific AM processes to generate spatially varying microstructures–and hence novel materials, remains largely untapped. This work presents a method for manufacturing materials through laser powder bed fusion (LPBF), in which control over the spatial variation in phase composition and mechanical properties is achieved. This technique is demonstrated using 17‐4 precipitation‐hardened stainless steel (17‐4PH), by controlling spatial modulation of energy densities during printing. This results in local control of ferrite/martensite volume fractions, allowing the fabrication of metal/metal architected composites with hard/brittle regions interspersed with soft/tough regions. Local variations of ~20% in tensile strength and ~150% in elongation are achieved, with a spatial resolution of ~100 microns. The approach is general and robust, fully compatible with commercially available LPBF equipment, and applicable to virtually any multi‐phase alloy system. This work shifts the paradigm from attempting to print components with uniform properties to manufacturing alloys with controlled spatial property gradients.

show abstract

Microstructural Evolution, Mechanical and Electrochemical Performance of Duplex Stainless Steel Fabricated by Wire Arc Additive Manufacturing with ER2209 Filler Wire

Karunanithi,

Arasappan,

Nallathambi

2024

steel research int.

View full text Add to dashboard Cite

This study examines the dependent relationship between microstructure, mechanical properties, and corrosion performance on the wire arc additive manufactured (WAAM) ER2209 duplex stainless steel (DSS). DSS is renowned for its corrosion resistance and mechanical strength, making it favorable for various applications. This study uses the gas metal arc welding (GMAW)‐ based WAAM technique to fabricate the wall structure using ER2209 DSS filler wire. Fine, equiaxed dendrites are formed along the build direction, with the austenite phase exceeding 70% due to the repeated heating and slow cooling inherent to WAAM process. X‐ray diffraction (XRD) confirms no brittle intermetallic phases. The results shows that varying austenite‐ferrite fractions significantly influences the anisotropy in mechanical properties between build and deposit directions. Along the build direction, the varying phase fraction causes difference in hardness of 19.59 HV0.3 and tensile strength of 20 MPa. The maximum tensile strength (787.08 MPa) is observed in the deposit direction, with a 52 MPa difference between the build and deposit directions. Tafel and EIS measurements indicated that WAAM samples corrosion resistance was almost close to wrought 2205 DSS. This study highlights WAAM's potential for defect‐free DSS parts and suggests post‐heat treatment to optimize microstructure and mechanical properties.

show abstract

Additive manufacturing of metal-based functionally graded materials: overview, recent advancements and challenges

Cited by 12 publications

References 218 publications

A Study on Metallographic and Machining Characteristics of Functionally Graded Material Produced by Directed Energy Deposition

A Study on Metallographic and Machining Characteristics of Functionally Graded Material Produced by Directed Energy Deposition

Microstructural Control of a Multi‐Phase PH Steel Printed with Laser Powder Bed Fusion

Microstructural Evolution, Mechanical and Electrochemical Performance of Duplex Stainless Steel Fabricated by Wire Arc Additive Manufacturing with ER2209 Filler Wire

Contact Info

Product

Resources

About