Laser Powder-Bed Fusion of Ceramic Particulate Reinforced Aluminum Alloys: A Review

Minasyan, Tatevik; Hussainova, Irina

doi:10.3390/ma15072467

Cited by 29 publications

(8 citation statements)

References 111 publications

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“…-TiC and TiB 2 are commonly used as reinforcements for AMC because of their thermal and chemical stability, and good wettability. The use of these two ceramic phases makes it possible to improve mechanical properties (such as Young's modulus, stiffness, strength, and hardness), and corrosion and wear performances [48,49]; -…”

Section: A6061 Ram2 Systemmentioning

confidence: 99%

Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Rosito

Vanzetti

Padovano

et al. 2023

Metals

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Despite the increasing interest in laser powder bed fusion (LPBF), only a few cast aluminum alloys are available for this process. This study focuses on improving the LPBF processability of the A6061 alloy, which is challenging due to its wide solidification range, the dendritic columnar grain growth, and consequent solidification cracking. To address these issues, in situ-synthesized grain refiners can be used to induce equiaxial grain growth and prevent crack formation. A6061 RAM2 powder—a mixture of A6061, Ti, and B4C—was characterized and processed using a low-power LPBF machine to create an in situ particle-reinforced metal matrix composite. Parameter optimization was performed to evaluate the effect of their variation on the printability of the alloy. Microstructural characterization of the samples revealed that the complete reaction and the synthesis of the ceramic reinforcement did not occur. However, TiAl3 was synthesized during the process and promoted a partial grain refinement, leading to the formation of equiaxial grains and preventing the formation of solidification cracks. The tensile tests carried out on the optimized samples exhibit superior mechanical properties compared to those of A6061 processed through LPBF.

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Section: A6061 Ram2 Systemmentioning

confidence: 99%

Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Rosito

Vanzetti

Padovano

et al. 2023

Metals

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“…Accordingly, the components Frontiers in Chemical Engineering frontiersin.org mechanical strength decreases and undesired anisotropic mechanical part properties are obtained (Tan et al, 2020). A promising approach to obtain crack-free parts is grain refinement by addition of nanoparticles, such as carbides, nitrides or borides (see Table 2) to aluminum alloys (Kusoglu et al, 2020;Sun et al, 2021;Minasyan and Hussainova, 2022). Heiland et al (2021) dry coated Al7075 with 2.5 wt% TiC nanoparticles in a ball mill and successfully produced crack-free parts by PBF-LB/M due to the action of TiC as a nucleating agent.…”

Section: Aluminum Alloy Feedstock Powdersmentioning

confidence: 99%

Dry powder coating in additive manufacturing

Schmidt

Peukert

2022

Front. Chem. Eng.

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Dry powder coating is used in many industries to tailor the bulk solid characteristics of cohesive powders. Within this paper, the state of the art of dry coating of feedstock materials for powder based additive manufacturing (AM) processes will be reviewed. The focus is on feedstock materials for powder bed fusion AM processes, such as powder bed fusion of polymers with a laser beam and powder bed fusion of metals with lasers or an electron beam. Powders of several microns to several ten microns in size are used and the feedstock’s bulk solid properties, especially the flowability and packing density are of immanent importance in different process steps in particular for powder dosing and spreading of powder layers onto the building area. All these properties can be tuned by dry particle coating. Moreover, possibilities to improve AM processability and to manipulate the resulting microstructure (c.f. grain refinement, dispersion strengthening) by adhering nanoparticles on the powders will be discussed. The effect of dry coating on the obtained powder properties along the whole AM process chain and the resulting part properties is assessed. Moreover, appropriate characterization methods for bulk solid properties of dry-coated AM powders are critically discussed.

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“…Over the past two decades, LPBF processes have been extensively studied with the aim of integrating them into mainstream manufacturing [4,[21][22][23][24][25][26][27][28]. However, poor surface finish and porosity have been reported to deteriorate the mechanical and corrosion properties of LPBF alloys [15,[29][30][31][32][33].…”

Section: Introductionmentioning

confidence: 99%

Influence of Spatter on Porosity, Microstructure, and Corrosion of Additively Manufactured Stainless Steel Printed Using Different Island Size

Vukkum,

Sanborn,

Shepherd

et al. 2024

Crystals

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Specimens of 316 L stainless steel were printed using laser powder bed fusion (LPBF), a popular metal additive manufacturing (AM) technique, with varying island sizes. Not many researchers have considered the impact of spatter while optimizing LPBF printing parameters. In this research, the influence of spatter was considered while also investigating the effect of varied island size on the microstructure, surface roughness, microhardness, and corrosion resistance of LPBF-316 L. No correlation was observed between surface roughness or microhardness and minor variations in island size. However, a correlation was drawn between varied island sizes and porosity in LPBF-316 L. The specimens associated with larger island sizes showed significantly enhanced corrosion resistance due to fewer manufacturing defects and reduced porosity, attributed to the minimal influence of the spatter. Based on analysis, the LPBF parameters were revised, which lead to superior corrosion resistance of LPBF-316 L, attributed to high density and reduced porosity.

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Laser Powder-Bed Fusion of Ceramic Particulate Reinforced Aluminum Alloys: A Review

Cited by 29 publications

References 111 publications

Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Processability of A6061 Aluminum Alloy Using Laser Powder Bed Fusion by In Situ Synthesis of Grain Refiners

Dry powder coating in additive manufacturing

Influence of Spatter on Porosity, Microstructure, and Corrosion of Additively Manufactured Stainless Steel Printed Using Different Island Size

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