Element Vaporization of Ti-6Al-4V Alloy during Selective Laser Melting

Zhang, Guo‐Hao; Chen, Jing; Yang, Zhenyu; Lu, Xufei; Lin, Xin; Huang, Weidong

doi:10.3390/met10040435

Cited by 30 publications

(18 citation statements)

References 25 publications

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“…Compared to other AM techniques such as Selective Laser Melting (SLM) (Zhang et al 2020), Directed Energy Deposition (DED) has a higher deposition efficiency, suitable for fabricating larger structural parts (Tang et al 2020). In DED processes the metal powder is concentrically blown into the molten pool induced by a high-energy laser beam moving according to user-defined building sequences .…”

Section: Introductionmentioning

confidence: 99%

Simulation-assisted investigation on the formation of layer bands and the microstructural evolution in directed energy deposition of Ti6Al4V blocks

Zhang

et al. 2021

Virtual and Physical Prototyping

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Section: Introductionmentioning

confidence: 99%

Simulation-assisted investigation on the formation of layer bands and the microstructural evolution in directed energy deposition of Ti6Al4V blocks

Zhang

et al. 2021

Virtual and Physical Prototyping

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“…Since aluminum is the element in Ti-6Al-4V with the highest saturated vapor pressure, it can be expected that it has a significant tendency to evaporation and vaporization loss during processing. The evaporation of aluminum by processing Ti-6Al-4V with different AM processes has already been reported in the literature (i.e., EBF 3 [ 4 , 52 ], E-PBF [ 53 , 54 ], or L-PBF [ 55 ]). Unlike L-PBF, the excessive aluminum loss was reported for vacuum based processes E-PBF (up to 30%) and EBF 3 (up to 39%) by Juechter et al [ 54 ] and Xu et al, respectively [ 4 ].…”

Section: Resultsmentioning

confidence: 99%

Wire-Based Additive Manufacturing of Ti-6Al-4V Using Electron Beam Technique

et al. 2020

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Electron beam freeform fabrication is a wire feed direct energy deposition additive manufacturing process, where the vacuum condition ensures excellent shielding against the atmosphere and enables processing of highly reactive materials. In this work, this technique is applied for the α + β-titanium alloy Ti-6Al-4V to determine suitable process parameter for robust building. The correlation between dimensions and the dilution of single beads based on selected process parameters, leads to an overlapping distance in the range of 70–75% of the bead width, resulting in a multi-bead layer with a uniform height and with a linear build-up rate. Moreover, the stacking of layers with different numbers of tracks using an alternating symmetric welding sequence allows the manufacturing of simple structures like walls and blocks. Microscopy investigations reveal that the primary structure consists of epitaxial grown columnar prior β-grains, with some randomly scattered macro and micropores. The developed microstructure consists of a mixture of martensitic and finer α-lamellar structure with a moderate and uniform hardness of 334 HV, an ultimate tensile strength of 953 MPa and rather low fracture elongation of 4.5%. A subsequent stress relief heat treatment leads to a uniform hardness distribution and an extended fracture elongation of 9.5%, with a decrease of the ultimate strength to 881 MPa due to the fine α-lamellar structure produced during the heat treatment. Residual stresses measured by energy dispersive X-ray diffraction shows after deposition 200–450 MPa in tension in the longitudinal direction, while the stresses reach almost zero when the stress relief treatment is carried out.

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“…For the post-heating models with post laser power of 60 W and 90 W and laser beam offset of 100 µm (Figure 5k,l), the secondary laser beam produced a higher peak temperature than the first melting laser beam, even though the delayed laser was with a reduced power compared with the melting laser. Note that several of the predicted peak temperatures (Figure 6h,k-m) exceeded the boiling temperature (3133 K) of Ti-6Al-4V material [31], which also occurred during physical manufacturing [32]. The predicted peak temperature of the majority of the material was below the boiling temperature of material.…”

Section: Temperature Profilesmentioning

confidence: 89%

Process Parameters Optimisation for Mitigating Residual Stress in Dual-Laser Beam Powder Bed Fusion Additive Manufacturing

Zhang

Abbott

Sasnauskas

et al. 2022

Metals

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Laser beam powder bed fusion (PBF-LB) additive manufacturing (AM) is an advanced manufacturing technology that manufactures metal components in a layer-by-layer manner. The thermal residual stress (RS) induced by the repeated heating–melting–cooling–solidification processes of AM is considered to limit the wider uptake of PBF-LB. A dual-laser beam PBF-LB strategy, with an additional auxiliary laser and reduced power, working in the same powder bed simultaneously, was recently proposed to lower RS within the manufactured components. To provide insights into the optimum PBF-LB AM configurations and process parameters for dual-laser PBF-LB, this study proposed three different coordinated heating strategies (i.e., parallel heating, post-heating, and preheating) of the auxiliary heat source. The temperature fields and RS of dual-laser beam PBF-LB, for Ti-6Al-4V with different process parameters, were computationally investigated and optimized by the thermo-mechanically coupled 3D models. Compared with the single beam PBF-LB, parallel heating, post-heating, and post-heating strategies were proved as effective approaches to reduce RS. Among these, the preheating scanning is predicted to be more effective in mitigating RS, i.e., up to a 10.41% RS reduction, compared with the single laser scanning. This work could be beneficial for mitigating RS and improve the mechanical properties of additively manufactured metal components.

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Element Vaporization of Ti-6Al-4V Alloy during Selective Laser Melting

Cited by 30 publications

References 25 publications

Simulation-assisted investigation on the formation of layer bands and the microstructural evolution in directed energy deposition of Ti6Al4V blocks

Simulation-assisted investigation on the formation of layer bands and the microstructural evolution in directed energy deposition of Ti6Al4V blocks

Wire-Based Additive Manufacturing of Ti-6Al-4V Using Electron Beam Technique

Process Parameters Optimisation for Mitigating Residual Stress in Dual-Laser Beam Powder Bed Fusion Additive Manufacturing

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