Multiphysics multi-scale computational framework for linking process–structure–property relationships in metal additive manufacturing: a critical review

Abstract

This review article provides a critical assessment of the progress made in computational modelling of metal-based additive manufacturing (AM) with emphasis on its ability to predict physical phenomena, concepts of microstructural evolution, residual stresses, role of multiple thermal cycles, and formation of multi-dimensional defects along with the achieved degree of experimental validation. The uniqueness of this article stems from the inclusion of comprehensive information on computational progress in the field of fusion-based, sintering-based, and mechanical deformation-based AM. A computational model's role in determining the process framework for the desired outcome of the set properties of the AM components is recognised while presenting the process-microstructure maps, thereby appraising computational ability towards the qualification of products. The inclusion of a detailed discussion on the bi-directional coupling of machine learning and physics-based computational models provides a futuristic roadmap for the digital twin of metal-based AM.

Additively Manufactured Alnico Permanent Magnet Materials—A Review

“…The additive manufacturing processes used for the fabrication of a metal-based composition can be categorized into three types based on temperature and time of interaction during the fabrication. Solid-state fabrication takes place at 0.7 times the liquidus temperature, sintering fabrication occurs at the liquidus temperature, and in a fusion-based process, fabrication takes place well above the liquidus temperature [42]. Figure 3 illustrates the various types of additive manufacturing processes classified based on energy source-material interaction time and temperature.…”

“…Through this gradual buildup, the final 3D part is formed [45]. Figure 4 illustrates the laser powder bed fusion process [42]. Powder size distribution and packing directly influence the density of the printed part [46].…”

“…In the L-DED process, both the laser beam and substrate onto which powder is being deposited are in motion, whereas in LPBF, only the laser beam is in motion [43]. The LPBF process has rapid cooling rates of the order of 10 6 K/s and 10 3 K/s in the L-DED process; this difference due to thermokinetics associated with the process leads to a finer grain size in the LPBF process and a coarser grain size in L-DED [42,43,47]. An ideal permanent magnet should exhibit highly anisotropic properties to ensure optimal magnetic performance.…”

“…In additive manufacturing, the crystallographic texture and grain morphology of the produced materials are profoundly affected by process parameters. The process parameters, such as platform temperature, laser power, scan speed, layer thickness, and cooling rate, have a direct influence on the thermokinetics of the process [42,48]. These process parameters determine the solidification rate and melt pool size and shape and temperature distribution within the melt pool [47].…”

Efficient Simulation of the Laser-Based Powder Bed Fusion Process Demonstrated on Open Lattice Materials Fabrication

“…Additive manufacturing (AM) processes have been proven to be the most advantageous method for the production of lattice materials contrary to conventional manufacturing processes, such as investment casting or textile weaving [9]. In AM methods, parts are fabricated in a layer-by-layer manner based on the input digital model, thus, providing more design freedom to engineers and manufacturers contrary to subtractive and forming manufacturing techniques [10][11][12][13][14][15][16]. Among the various AM processes, the Laser-based Powder Bed Fusion (L-PBF) process is widely adopted in the industry and has reached a high level of maturity, with fabricated parts of excellent quality produced by various types of metal alloys [5,10].…”