Influence of aluminium powder aging on Directed Energy deposition

Silva, Adrien Da; Belelli, Filippo; Lupi, Giorgia; Bruzzo, Francesco; Brandau, Benedikt; Maier, Lukáš; Pesl, Alexander; Frostevarg, Jan; Casati, Riccardo; López, Elena; Kaplan, Alexander

doi:10.1016/j.matdes.2022.110677

Cited by 15 publications

(11 citation statements)

References 44 publications

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“…Generally, Al powders have a dense alumina layer on the surface, which may further reduce their laser absorption rate, and the reduction degree depends on the thickness of the alumina layer [40,59]. The presence of an oxide layer may also influence the heat capture of inflight powders and melt pools.…”

Section: High Oxidation Sensitivity and Hydrophilicitymentioning

confidence: 99%

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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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Section: High Oxidation Sensitivity and Hydrophilicitymentioning

confidence: 99%

“…In addition, Al alloy powder has a high humidity requirement. If the powder is damp, sending the powder out of the powder hopper is difficult, leading to nozzle blockage [59].…”

Section: Poor Powder and Melt Fluiditymentioning

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 main findings of [ 15 ] have pertained to the mechanical properties (ultimate tensile strength (UTS) and elongation at the break of specimens, respectively, built with virgin and reused powder are 565 MPa, 13% and 537 MPa, 11%) and porosity (0.06% for samples made from virgin powder compared to 0.15% for samples made for the reused powder). In addition, the authors of [ 16 ] analysed properties of AlSi10Mg alloy aged in air and used for direct-energy deposition (DED); they found out that the increase in oxygen content influences the processability of the powder and the properties of the final specimens.…”

Section: Introductionmentioning

confidence: 99%

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

et al. 2022

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Additive manufacturing (AM) is dynamically developing and finding applications in different industries. The quality of input material is a part of the process and of the final product quality. That is why understanding the influence of powder reuse on the properties of bulk specimens is crucial for ensuring the repeatable AM process chain. The presented study investigated the possibility of continuous reuse of AlSi7Mg0.6 powder in the laser powder bed fusion process (LPBF). To date, there is no study of AlSi7Mg0.6 powder reuse in the LPBF process to be found in the literature. This study aims to respond to this gap. The five batches of AlSi7Mg0.6 powder and five bulk LPBF samples series were characterised using different techniques. The following characteristics of powders were analysed: the powder size distribution (PSD), the morphology (scanning electron microscopy—SEM), the flowability (rotating drum analysis), and laser light absorption (spectrophotometry). Bulk samples were characterised for microstructure (SEM), chemical composition (X-ray fluorescence spectrometry—XRF), porosity (computed tomography—CT) and mechanical properties (tensile, hardness). The powder was reused in subsequent processes without adding (recycling/rejuvenation) virgin powder (collective ageing powder reuse strategy). All tested powders (powders P0–P4) and bulk samples (series S0–S3) show repeatable properties, with changes observed within error limits. Samples manufactured within the fifth reuse cycle (series S4) showed some mean value changes of measured characteristics indicating initial degradation. However, these changes also mostly fit within error limits. Therefore, the collective ageing powder reuse strategy is considered to give repeatable LPBF process results and is recommended for the AlSi7Mg0.6 alloy within at least five consecutive LPBF processes.

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“…DED techniques have been used to successfully produce claddings and/or fully threedimensional components with different alloys, such as titanium [1,2], nickel [3,4], copper [5] and aluminium [6] alloys, tool steels [7,8] and stainless steels [9,10]. One additional material group that has been DED-processed are Maraging steels, which consist of high-strength, precipitation hardened steels.…”

Section: Introductionmentioning

confidence: 99%

Tensile Properties of As-Built 18Ni300 Maraging Steel Produced by DED

et al. 2022

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The mechanical behaviour of as-built DED-produced 18Ni300 Maraging steel was studied by manufacturing a wall-like structure from which three different specimen types were obtained: specimens in which the loading direction was the same as the printing direction (vertical), specimens in which these two directions were perpendicular (horizontal), and bimetallic specimens in which the interface between the AISI 1045 substrate and the 18Ni300 steel was tested. The yield strength of the produced samples was 987.9±34.2, 925.9±89.7 and 486.7±47.2MPa for the vertical, horizontal and bimetallic specimens, respectively, while the elongation to failure was 9.4±1.9, 18.3±2.3 and 14.06±0.6% in the same order. The latter specimen failed within the substrate-comprised portion of the specimen. Additionally, the fracture surfaces were analysed through scanning electron microscopy, concluding that while both surfaces consist of dimples, the horizontal specimen presented microporosities with a reduced diameter. A microhardness analysis in the printed wall-like structure following the printing direction yielded an average hardness of 392±21 HV0.3, with fluctuations along the build direction mostly within one standard deviation.

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Influence of aluminium powder aging on Directed Energy deposition

Cited by 15 publications

References 44 publications

Review on laser directed energy deposited aluminum alloys

Review on laser directed energy deposited aluminum alloys

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

Tensile Properties of As-Built 18Ni300 Maraging Steel Produced by DED

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