Microstructure and mechanical property considerations in additive manufacturing of aluminum alloys

Abstract

Abstract

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

“…[234] AlSi alloys show an inhomogeneous composition and grain size across each individual scan track and layer, leading to a heterogeneous distribution of Si-particles during the HT. [24,95,151,240,241] www.advancedsciencenews.com www.aem-journal.com hardening stages, thus removing most of the location dependencies. [235] Yet, a post HT still increases the ductility of AlSi alloys and was found as a suitable option for an adjustment of their mechanical properties.…”

“…[240,241] www.advancedsciencenews.com www.aem-journal.com of the studies to date is provided in Table 29, whereby all studies focus on the mode 1 crack opening case. An overview Dedicated publications to this topic can be found here.…”

“…[30] Comprehensive overview about available AM technologies, their particular process conduct; categorization of the areas of application for the specific technique [31] Comparative review, comparing SLM fabrication of metals with traditional fabrication methods [124] Detailed review about the mechanical properties and the process conduct of aluminum alloys fabricated with PBF; various fusing principles addressed, ranging from indirect SLS (with binding media) to full melting (SLM) [24] Review about the various AM techniques with the focus of providing selection guidelines to distinguish which process to choose for a given set of requirements [32] Review on the process control in laser-based PBF and the underlying physical principles [46] Review about the SLM process, the process conduct, the gain in interest in the technology over time, and achievable properties [25] Review about numerical modeling and simulation of PBF involving full melting of the raw material [322] Comparison of PBF techniques, with the focus on SLM and EBM and the available machinery; highlights the geometrical flexibility on documented studies and show-cases [323] Review about achievable mechanical properties of metal fabricated with DED and PDF techniques [23] Review on PBF and DED, with the focus on binding mechanism, available raw materials and the resulting microstructure [26] Detailed review about the mechanical properties of aluminum alloys fabricated with DED and PBF techniques [324] Review/discussion of the utilization of the three main aluminum types (pure, casting, wrought chemistries) and their processing with PBF and DED techniques [241] Detailed review about the mechanical properties of Ti6Al4V fabricated with DED and PBF techniques [247] Review about the SLM process conduct for pure Ti and Ti6Al4V, including expectable mechanical properties [192] Overview about emerging high performance materials, such as particle-reinforced composites, hard-metals and intermetallic phases, processed with PBF [6] Review about SLS and SLM using pure ceramic powder without binding media [325] Comprehensive summary of laser processing technologies and the laser material interaction [53] Review about topology-optimization to achieve desired mechanical properties in porous metal structures and scaffolds; major focus are bone scaffolds and orthopaedic implants, utilising SLM and EBM with titanium alloys, biodegradable metals and shape-memory alloys (NiTi) [30] Comprehensive overview about available AM technologies, their particular process conduct; categorization of the areas of application for the specific technique …”

Fusion‐Based Additive Manufacturing for Processing Aluminum Alloys: State‐of‐the‐Art and Challenges

“…In spite of their many advantages − light weight, high specific strength, and good corrosion resistance − aluminum alloys had until recently received much less attention in comparison with other metallic alloys . Indeed, the costs of Al parts produced by conventional routes is reasonably low when compared, for example, to titanium that is more difficult to machine .…”

“…The high reflectivity of Al alloys for laser wavelengths generally used in A.M. has often been cited as an issue, although this point has recently been questioned . The fairly high thermal conductivity of Al alloys, their propensity to form adherent oxides, their relatively wide solidification range, and the relatively poor flowability of Al powders as a consequence of their low density, are all significant obstacles for the generalized use of A.M. for the production of Al parts. In particular, high strength Al alloys such as the 2xxx, 6xxx, and 7xxx series, that are of great interest for the aeronautic and transportation industries, are known to be hardly weldable and are thus poorly suited for A.M …”