Effects of defects on mechanical properties in metal additive manufacturing: A review focusing on X-ray tomography insights

Plessis, Anton du; Yadroitsava, Ina; Yadroitsev, Igor

doi:10.1016/j.matdes.2019.108385

Cited by 391 publications

(121 citation statements)

References 89 publications

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“…Hybrid specimens, with their AM part manufactured via SLM were tested for microstructural variations, presence of defects, uniaxial tensile ductility and fracture toughness for several configurations. While defects were found in both the AM part of the specimen and its wrought counterpart, their characteristics were not different from those reported in the literature for other SLM Ti-6Al-4V specimens [43,46,47]. Moreover, the spatial variability of defects did not exhibit any correlation with the location of the AM-wrought interface.…”

Section: Discussioncontrasting

confidence: 47%

Ti-6Al-4V hybrid structure mechanical properties—Wrought and additive manufactured powder-bed material

Dolev

Osovski

Shirizly

2021

Additive Manufacturing

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The implementation of additive manufacturing techniques in the production of mission critical structural components is challenged by its low throughput and limited build envelope. In recent years, hybrid production methods are emerging to bridge between the build volume and high throughput of conventional production methods and the design freedom enabled by additive manufacturing. The repeatability of material properties and the quality of the interface between the additive manufactured and wrought material are crucial for the adoption of hybrid manufacturing techniques by the industry. Here, the tensile behavior and fracture toughness of a hybrid Ti-6Al-4V alloy are examined in detail. Ti-6Al-4V pre-forms were built onto a wrought Ti-6Al-4V start-plate and extracted via milling. Compact tension and uniaxial tension specimens extracted from the hybrid pre-forms demonstrated good fracture and properties with no preference for crack growth in neither the AM nor wrought materials. Microstructural characterization revealed a 40 mm transition layer into the wrought material which ends abruptly with no evidence of a gradually decaying heat-affected zone. The hybrid manufacturing approach studied here expands the current limitations of large-scale critical components with fine features and allow such structures to be produced with a higher throughput.

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Section: Discussioncontrasting

confidence: 47%

Ti-6Al-4V hybrid structure mechanical properties—Wrought and additive manufactured powder-bed material

Dolev

Osovski

Shirizly

2021

Additive Manufacturing

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“…The additive manufacturing process of metals has been analyzed to identify and optimize the relation between the process parameters, the internal metallurgical defects, and the residual thermal stresses that have a significant impact especially on the mechanical properties of the parts [34][35][36][37][38]. The relation between the printing parameters and the resulting surface quality, especially for convoluted structures, is still under investigation [39,40].…”

Section: Introductionmentioning

confidence: 99%

Selective Laser Melting and Electron Beam Melting of Ti6Al4V for Orthopedic Applications: A Comparative Study on the Applied Building Direction

et al. 2020

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The 3D printing process offers several advantages to the medical industry by producing complex and bespoke devices that accurately reproduce customized patient geometries. Despite the recent developments that strongly enhanced the dominance of additive manufacturing (AM) techniques over conventional methods, processes need to be continually optimized and controlled to obtain implants that can fulfill all the requirements of the surgical procedure and the anatomical district of interest. The best outcomes of an implant derive from optimal compromise and balance between a good interaction with the surrounding tissue through cell attachment and reduced inflammatory response mainly caused by a weak interface with the native tissue or bacteria colonization of the implant surface. For these reasons, the chemical, morphological, and mechanical properties of a device need to be designed in order to assure the best performances considering the in vivo environment components. In particular, complex 3D geometries can be produced with high dimensional accuracy but inadequate surface properties due to the layer manufacturing process that always entails the use of post-processing techniques to improve the surface quality, increasing the lead times of the whole process despite the reduction of the supply chain. The goal of this work was to provide a comparison between Ti6Al4V samples fabricated by selective laser melting (SLM) and electron beam melting (EBM) with different building directions in relation to the building plate. The results highlighted the influence of the process technique on osteoblast attachment and mineralization compared with the building orientation that showed a limited effect in promoting a proper osseointegration over a long-term period.

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“…The mechanism of the increase in surface hardness with respect to depth is a result of grain size refinement and work hardening induced by plastic strain [33]. Specifically, in AM materials, the elimination of surface defects such as porosities, cracks, etc., may also be responsible for the increase in surface hardness with respect to depth [34]. responsible for the lower surface hardness in comparison with the subsurface [32].…”

Section: Hardness Testmentioning

confidence: 99%

Mechanical and Tribological Characteristics of Cladded AISI 1045 Carbon Steel

et al. 2020

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This study introduces a newly developed cladding device, through printing AISI 1045 carbon steel as single and double layers onto American Society for Testing and Materials (ASTM) H13 tool steel plate. In this study, the mechanical and tribological characteristics of single and double layers were experimentally investigated. Both layers were polished first and then subjected to ultrasonic nanocrystal surface modification (UNSM) treatment to improve the mechanical and tribological characteristics. Surface roughness, surface hardness and depth profile measurements, and X-ray diffraction (XRD) analysis of the polished and UNSM-treated layers were carried out. After tribological tests, the wear tracks of both layers were characterized by scanning electron microscopy (SEM) along with energy-dispersive X-ray spectroscopy (EDX). The surface roughness (Ra and Rz) of the single and double UNSM-treated layers was reduced 74.6% and 85.9% compared to those of both the as-received layers, respectively. In addition, the surface hardness of the single and double layers was dramatically increased, by approximately 23.6% and 23.4% after UNSM treatment, respectively. There was no significant reduction in friction coefficient of both the UNSM-treated layers, but the wear resistance of the single and double UNSM-treated layers was enhanced by approximately 9.4% and 19.3% compared to the single and double polished layers, respectively. It can be concluded that UNSM treatment was capable of improving the mechanical and tribological characteristics of both layers. The newly developed cladding device can be used as an alternative additive manufacturing (AM) method, but efforts and upgrades need to progress in order to increase the productivity of the device and also improve the quality of the layers.

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Effects of defects on mechanical properties in metal additive manufacturing: A review focusing on X-ray tomography insights

Cited by 391 publications

References 89 publications

Ti-6Al-4V hybrid structure mechanical properties—Wrought and additive manufactured powder-bed material

Ti-6Al-4V hybrid structure mechanical properties—Wrought and additive manufactured powder-bed material

Selective Laser Melting and Electron Beam Melting of Ti6Al4V for Orthopedic Applications: A Comparative Study on the Applied Building Direction

Mechanical and Tribological Characteristics of Cladded AISI 1045 Carbon Steel

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