Laser metal deposition and selective laser melting of Fe–28 at.% Al

Abstract

The iron aluminide Fe 3 Al has been successfully processed by selective laser melting (SLM) and laser metal deposition (LMD). Process parameters have been determined by which defect free and dense (.99.5%) samples were produced. However, due to the low thermal conductivity of Fe 3 Al, preheating the substrate to 200°C was necessary to prevent cracking during cooling. Microstructural characterization by electron backscatter diffraction (EBSD) showed that in spite of the high cooling rates large elongated grains grew in the building direction, more distinctive for SLM than for LMD. These grains show a continuous change in the crystallographic orientation. Evaluation of the compressive flow stress showed that the anisotropic microstructure results in anisotropic mechanical properties, depending whether the samples are loaded in building direction or perpendicular to it. The alloy shows a very high strength up to 600°C and -concerning the coarse microstructure -becomes ductile already at low temperatures.

A Review of Metal Fabricated with Laser‐ and Powder‐Bed Based Additive Manufacturing Techniques: Process, Nomenclature, Materials, Achievable Properties, and its Utilization in the Medical Sector

“…[110,122,123] This phenomenon is greatly attributed to the faster processing, which minimizes the losses of energy, which are significant at low build rates. [64,71] However, the reported results differ: In the case of an AlSi alloy, the reproduction of the values [45,87,101,157,[160][161][162][163][164] dedicated study to this topic [121] 1.4539; 904L 99 [165] 1.2709; 18Ni Marage 300; hot work steel; EOS MS1 >99 99.99 [51,146,[166][167][168][169] 1.2343; H11 (tool steel) %100 [45] 1.2344; H13 (tool steel) >99 99.99 [119,170,171] H20 (tool steel); EOS DirectSteel >97.5 99.5 [172,173] 1.2764 (case-hardening steel) >99 [50] X110CrMoVAl 8-2 (cold work steel) %100 [174] 1.4542; 17-4PH (age-hardenable stainless steel) $99 >99.9 [55,[175][176][177] M2 HSS >90 99.8 [118,146,178] Fe-28 at% Al 99.5 [179] Fe-35 wt% Al (intermetallic) 98 [180] Fe-0.8 wt% C 93 [181] Fe-2 wt% C 92.0 [182] Fe-30Ni 98.0 [183] Fe-12Ni-4Cr 99.5 [183]...…”

“…Type/Alloy Common a) max. References pure Fe 97.5 99.0 [156,157] 1.4307; 304L 92 %100 [158,159] 1.4404; 316L 99.0 99.97 [45,87,101,157,[160][161][162][163][164] dedicated study to this topic [121] 1.4539; 904L 99 [165] 1.2709; 18Ni Marage 300; hot work steel; EOS MS1 >99 99.99 [51,146,[166][167][168][169] 1.2343; H11 (tool steel) %100 [45] 1.2344; H13 (tool steel) >99 99.99 [119,170,171] H20 (tool steel); EOS DirectSteel >97.5 99.5 [172,173] 1.2764 (case-hardening steel) >99 [50] X110CrMoVAl 8-2 (cold work steel) %100 [174] 1.4542; 17-4PH (age-hardenable stainless steel) $99 >99.9 [55,[175][176][177] M2 HSS >90 99.8 [118,146,178] Fe-28 at% Al 99.5 [179] Fe-35 wt% Al (intermetallic) 98 [180] Fe-0.8 wt% C 93 [181] Fe-2 wt% C 92.0 [182] Fe-30Ni 98.0 [183] Fe-12Ni-4Cr 99.5 [183] Fe-29Ni-8Cu-P 97.5 [184] Fe85Cr4Mo8V2C1 (tool steel) >99.6 [185]…”

Transition Metal Aluminide Coatings and Initial Steps on Additive Manufacturing

“…There are some reports on additive manufacturing of iron aluminides, i.e. 3D laser cladding, laser metal deposition (LMD), laser engineered net shaping (LENS) and selective laser melting (SLM) processes [29][30][31][32][33][34][35][36]. SLM derives from the selective laser sintering (SLS) process because instead of sintering or partial melting, complete melting of powder occurs; also for SLS postprocessing is required.…”

“…LENS has been mostly used for obtaining functionally graded materials (FGMs), either Fe 3 Al/ SS316L or Fe/FeAl [30,33,34], allowing to produce tubes with good shape and a high metallurgical quality (Figure 2). LENS enables the production of metal components through a process of metal powder sintering aided with pre-designed three-dimensional computer-aided design (CAD) models.…”

Laser metal deposition additive manufacturing of TiC/Inconel 625 nanocomposites: Relation of densification, microstructures and performance

“…The nozzle is designed in order that the powder streams converge at the same point on the focused laser beam. [19][20][21] LMD provides a powerful way in preparing complex components and allows a high degree of flexibility in the control of the deposited components' geometry, composition, microstructure and performance. 22 During LMD process, the material experiences a rapid heating and cooling cycle, which induces a fine microstructure that differs substantially from that of conventional methods processed material.…”