Feature-based volumetric defect classification in metal additive manufacturing

Poudel, Arun; Yasin, Mohammad Salman; Ye, Jiafeng; Liu, Jia; Vinel, Aleksandr; Shao, Shuai; Shamsaei, Nima

doi:10.1038/s41467-022-34122-x

Cited by 56 publications

(17 citation statements)

References 43 publications

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“…Extensive research has been conducted in this field; the processing of Ti6Al4V alloy, the most popular titanium-based alloy, has received extensive attention. [25][26][27][28][29][30][31][32][33] In terms of processability, Nguyen et al [34] reviewed the processability of Ti6Al4V by various AM methods, including electron beam melting (EBM), laser powder bed fusion (L-PBF), and directed energy deposition (DED) methods. L-PBF and DED methods exhibit comparable strength to the conventionally produced counterparts, up to 25% higher.…”

Section: Doi: 101002/adem202301122mentioning

confidence: 99%

Additive Manufacturing of Titanium Alloys: Processability, Properties, and Applications

Mosallanejad,

Abdi,

Karpasand

et al. 2023

Adv Eng Mater

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The restricted number of materials available for additive manufacturing (AM) technologies is a determining impediment to AM growing into sectors and providing supply chain relief. AM, in particular, is regarded as a trustworthy manufacturing technology to replace the traditional ones for Ti alloy components. Furthermore, the AM processability of Ti alloys and their features, such as microstructure, texture, and mechanical properties, is strongly dependent on the chemical composition of the processed alloy. It is essential to consider the ultimate applications as well. β Ti alloys are gaining popularity in the biomedical industry, while α + β Ti alloys are increasingly utilized for producing components in the automotive and aerospace sectors. Consequently, the topic has garnered considerable interest, and the current text reviews the advances during the last 10 years in this area to facilitate the pathway from the demanded Ti alloy to the best‐fit AM procedure. While systematically reviewing the works published in the literature, the current text attempts to establish a link between the production method, feedstock type, chemical composition, and the ultimate application. This review also features practical applications of Ti components produced by metal AM methods and offers prospective possibilities and industrial applications.

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Section: Doi: 101002/adem202301122mentioning

confidence: 99%

Additive Manufacturing of Titanium Alloys: Processability, Properties, and Applications

Mosallanejad,

Abdi,

Karpasand

et al. 2023

Adv Eng Mater

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“…In this fatigue regime, crack initiation dominated most of the life with the near surface pores and LoF's, which were present in all of the conditions, acting as stress concentration sites. These defects had varying characteristics (i.e., size, shape, and distance to the surface) 55,56 from specimen to specimen and, thus, could lead to varying degrees of stress concentrations. In comparison, at the higher strain level of 0.005 mm/mm, the fatigue scatter was observed to be lower.…”

Section: Fatigue Behaviormentioning

confidence: 99%

“…This was most likely due to the process parameters for Renishaw AM250 having lower energy density values than EOS, which resulted in large LoFs present in all of the specimens. However, there could be other defect characteristics that influenced the results, 55,63 which would explain why some specimens had different fatigue lives despite their ffiffiffiffiffiffiffiffiffi area p s being similar. Scanning electron micrographs for some of the fracture surfaces of the Renishaw specimens are presented in Figure 12.…”

Section: Fatigue Behaviormentioning

confidence: 99%

Tensile and fatigue behaviors of additively manufactured AlSi10Mg: Effect of solutionizing and aging heat treatments

Baig

Ghiaasiaan

Shao

et al. 2023

Fatigue Fract Eng Mat Struct

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The effects of various heat treatments on the microstructure and mechanical properties of laser beam powder bed fused AlSi10Mg were investigated. Specimens were solutionized at three different temperatures of 425 C, 475 C, and 525 C followed by natural aging (T4) prior to microstructural and mechanical characterization. In addition, the effect of aging was studied by artificially aging (i.e., T7) some of the solutionized specimens at 165 C. Solutionizing at all temperatures was observed to fully dissolve the additive manufacturing (AM) induced dendritic microstructure, leaving bulky Si and needle-shaped β-AlFeSi precipitates in the grain interiors and boundaries. Tensile results revealed that T4 specimens exhibited more ductility, while T7 specimens showed substantially higher strengths with slightly reduced ductility. Interestingly, no significant effect of heat treatment on strain-life fatigue behavior was observed. Fractography found the Si particles to be responsible for tensile fracture, while AM volumetric defects were the main initiators of fatigue cracks.aluminum, fatigue, laser beam powder bed fusion (LB-PBF/L-PBF), microstructure, tensile Highlights• Effect of heat treatments on tensile and fatigue behavior of L-PBF AlSi10Mg studied.• T7 treatment led to higher tensile strengths than T4, but similar fatigue lives.• Tensile failure initiated from Si-particle fracture or debonding from matrix.• Fatigue life was affected by the size of crack initiators, that is, volumetric defects. | INTRODUCTIONAluminum alloys are commonly used in various industries because of their superior strength/stiffness to weight ratio compared to other alloys. 1,2 Among various Al alloys, AlSi10Mg as a cast alloy 2 has historically been used to fabricate complex/thin-walled geometries. Recently, processing AlSi10Mg through additive manufacturing (AM) has shown to be very promising as intricate, lightweight parts can be manufactured without

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“…With the rapid progress of modern manufacturing industry, metal additive manufacturing (AM) technologies are booming in high-end manufacturing fields such as electric vehicles, aerospace and biomedicine [1][2][3][4]. The global metal AM market is expected to reach about 8 billion USD by 2025, with a compound annual growth rate of 34.9% [5].…”

Section: Introductionmentioning

confidence: 99%

Review on laser directed energy deposited aluminum alloys

Liu,

Chen,

Qiu

et al. 2024

Int. J. Extrem. Manuf.

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The lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing to process high-value Al parts. As a mainstream additive manufacturing technique, laser directed energy deposition (LDED) shows good scalability to meet requirements for large-format components manufacturing and repairing. However, LDED Al alloys are highly challenging due to the inherent poor printability (e.g., low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review gains a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, elements evaporation and resultant inferior mechanical properties (than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improve the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmarking mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. The future opportunities and perspectives in LDED high-performance Al alloys are also outlooked.

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Feature-based volumetric defect classification in metal additive manufacturing

Cited by 56 publications

References 43 publications

Additive Manufacturing of Titanium Alloys: Processability, Properties, and Applications

Additive Manufacturing of Titanium Alloys: Processability, Properties, and Applications

Tensile and fatigue behaviors of additively manufactured AlSi10Mg: Effect of solutionizing and aging heat treatments

Review on laser directed energy deposited aluminum alloys

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