An ultra-high strength martensitic steel fabricated using selective laser melting additive manufacturing: Densification, microstructure, and mechanical properties

Seede, Raiyan; Shoukr, David; Zhang, Bing; Whitt, Austin; Gibbons, Sean; Flater, Philip; Elwany, Alaa; Arróyave, Raymundo; Караман, И.

doi:10.1016/j.actamat.2019.12.037

Cited by 184 publications

(79 citation statements)

References 48 publications

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“…Compared with traditional manufacturing, AM (abbreviations used in the paper are summarized in Table 1) techniques have the ability to produce complex components with less waste of materials and energy, and shorter processing cycle [2,3]. To date, AM has successfully processed a variety of metal components [4][5][6][7][8][9]. Metal additive manufacturing processes utilize laser beam, electron beam, or arc as the heat source and the feedstock material is in the form of powder, wire, or sheet [1,10].…”

Section: Introductionmentioning

confidence: 99%

Wire Arc Additive Manufacturing of Stainless Steels: A Review

et al. 2020

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Wire arc additive manufacturing (WAAM) has been considered as a promising technology for the production of large metallic structures with high deposition rates and low cost. Stainless steels are widely applied due to good mechanical properties and excellent corrosion resistance. This paper reviews the current status of stainless steel WAAM, covering the microstructure, mechanical properties, and defects related to different stainless steels and process parameters. Residual stress and distortion of the WAAM manufactured components are discussed. Specific WAAM techniques, material compositions, process parameters, shielding gas composition, post heat treatments, microstructure, and defects can significantly influence the mechanical properties of WAAM stainless steels. To achieve high quality WAAM stainless steel parts, there is still a strong need to further study the underlying physical metallurgy mechanisms of the WAAM process and post heat treatments to optimize the WAAM and heat treatment parameters and thus control the microstructure. WAAM samples often show considerable anisotropy both in microstructure and mechanical properties. The new in-situ rolling + WAAM process is very effective in reducing the anisotropy, which also can reduce the residual stress and distortion. For future industrial applications, fatigue properties, and corrosion behaviors of WAAMed stainless steels need to be deeply studied in the future. Additionally, further efforts should be made to improve the WAAM process to achieve faster deposition rates and better-quality control.

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Section: Introductionmentioning

confidence: 99%

Wire Arc Additive Manufacturing of Stainless Steels: A Review

et al. 2020

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“…To this end, Seede et al proposed a framework to determine the appropriate process parameters that do not cause keyholing, balling, or residual unmelted areas by combining single-track tests and analytical model evaluations [11]. The single-track test is a method used to obtain a melt pool on a line by scanning a laser only on a single line under various fabrication conditions; this test can be performed in a shorter duration compared with fabricating parts of several tens of square millimeters.…”

Section: Introductionmentioning

confidence: 99%

Process Parameter Optimization Framework for the Selective Laser Melting of Hastelloy X Alloy Considering Defects and Solidification Crack Occurrence

et al. 2021

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Recent years have witnessed increasing demand for selective laser melting (SLM) in practical applications; however, determining the appropriate process parameter range remains challenging. In this study, a framework was developed to determine the appropriate process parameter range considering the occurrence of defects and cracks by conducting a single-track test and thermal elastoplastic analysis. Keyholing, balling, and the residual unmelted regions were considered defects. The occurrence of solidification cracking, which is predominant in the SLM of solution-strengthened Ni-based alloys, was considered. Using the proposed framework, we could fabricate a part with largely no defects or cracks, except for the edges, under the determined optimal process parameters.

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“…Recently, laser cladding, as a novel metal additive manufacturing technology, has achieved marked progress [ 13 , 14 ], showing the capability of repairing damaged rails online [ 15 , 16 , 17 , 18 , 19 , 20 ] with the advantages of convenience, high quality of the repair layer and low cost compared with the traditional replacement method. However, the precondition for online rail-repair using the laser cladding technology is to acquire the complete closed mesh model of the scratch data.…”

Section: Introductionmentioning

confidence: 99%

Establishment of the Complete Closed Mesh Model of Rail-Surface Scratch Data for Online Repair

Guo

Huang

Liu

et al. 2020

Sensors

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Rail surface scratching occurs with increasing frequency, seriously threatening the safety of vehicles and humans. Online repair of rail-surface scratches on damaged rails with scratch depths >1 mm is of increased importance, because direct rail-replacement has the disadvantages of long operation time, high manpower and high material costs. Advanced online repair of rail-surface scratch using three-dimensional (3D) metal printing technology such as laser cladding has become an increasing trend, desperately demanding a solution for the fast and precise establishment of a complete closed mesh model of rail-surface scratch data. However, there have only been limited studies on the topic so far. In this paper, the complete closed mesh model is well established based on a novel triangulation algorithm relying on the topological features of the point-cloud model (PCM) of scratch-data, which is obtained by implementing a scratch-data-computation process following a rail-geometric-feature-fused algorithm of random sample consensus (RANSAC) performed on the full rail-surface PCM constructed by 3D laser vision. The proposed method is universal for all types of normal-speed rails in China. Experimental results show that the proposed method can accurately acquire the complete closed mesh models of scratch data of one meter of 50 Kg/m-rails within 1 min.

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An ultra-high strength martensitic steel fabricated using selective laser melting additive manufacturing: Densification, microstructure, and mechanical properties

Cited by 184 publications

References 48 publications

Wire Arc Additive Manufacturing of Stainless Steels: A Review

Wire Arc Additive Manufacturing of Stainless Steels: A Review

Process Parameter Optimization Framework for the Selective Laser Melting of Hastelloy X Alloy Considering Defects and Solidification Crack Occurrence

Establishment of the Complete Closed Mesh Model of Rail-Surface Scratch Data for Online Repair

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