Opportunities and challenges in additive manufacturing of functionally graded metallic materials via powder-fed laser directed energy deposition: A review

Ansari, Mohammad; Jabari, Elahe; Toyserkani, Ehsan

doi:10.1016/j.jmatprotec.2021.117117

Cited by 111 publications

(28 citation statements)

References 80 publications

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“…The studied eutectic alloys were dispersion-strengthened natural composites consisting of relatively soft matrix phase: alloyed austenite or pearlite, strengthened with a hard and wear-resistant (Fe, Mn) 23 (C, B) 6 phase. By changing the contents of the alloying elements, it is possible to obtain two or more phases in equilibrium [17,[38][39][40][41][42][43][44][45][46][47][48][49][50]. By balancing the four components, one can obtain an alloy with the required combination of carbide content and composition.…”

Section: Discussionmentioning

confidence: 99%

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Phase Equilibrium and Microstructure Examinations of Eutectic Fe-C-Mn-B Alloys

Pashechko

Тіsov

2022

Materials

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In this study, we analyzed the quaternary Fe-C-Mn-B system to create new eutectic cast alloys for coating deposition and additive manufacturing. Experimental samples were fabricated via the wire arc manufacturing method with argon shielding using Kemppi Pro 5200 Evolution equipment. Annealing was performed in a vacuum electric furnace at 1273 K for 350 h. For phase analyses, Jeol Superprobe 733 equipment was used. Metallographic and differential thermal analyses were used to reveal the eutectic structure of the samples. Examinations of the quaternary Fe-C-Mn-B system demonstrated that several eutectic alloys existed in the system. Four isothermal pseudo-ternary sections of the Fe-C-Mn-B system were studied: “Fe3B”-Fe3C-“Fe3Mn”; Fe2B-“Fe2C”-“Fe2Mn”; “Fe3B”-Fe3C-“Fe1.2Mn”; “Fe23B6”-“Fe23C6”-“Fe23Mn”. Broad eutectic concentrations enabled us to overcome parameter fluctuations during additive manufacturing. In each isothermal section, two dissimilar phase regions were determined: one with a ternary Fe-C-B composition and the other with a ternary Fe-C-Mn composition. Depending on the manganese content, two types of solid solutions could be formed: (Fe, Mn)α or (Fe, Mn)γ.

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Section: Discussionmentioning

confidence: 99%

“…Metal-based additive manufacturing involves the melting of powders or wires composed of the target material [16]. Powder-cored wires are also often used [17]. The compositional bond layer [18] allows one to bind steel with almost any material, including other types of steel, titanium, and nickel alloys.…”

Section: Introductionmentioning

confidence: 99%

Phase Equilibrium and Microstructure Examinations of Eutectic Fe-C-Mn-B Alloys

Pashechko

Тіsov

2022

Materials

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“…LPBF can realise the rapid fabrication of complex parts, shorten the development cycle of the product, improve the utilisation of materials, and reduce the development cost [1][2][3][4]. Unlike conventional casts or fabrications, the defects existing inside the additive forming parts had pores, poor fusion and cracking, and the morphology of the pores was regular spherical or spherical like with a random distribution [5,6].…”

Section: Introductionmentioning

confidence: 99%

Evolution of material removal in the magnetorheological polishing of Ti6Al4V by laser power bed fusion

Bao

Chen

et al. 2022

Mechanics & Industry

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This study aimed to obtain super smooth surface medical implant laser power bed fusion Ti6Al4V samples. A self-modified magnetorheological polishing device and polishing fluid were used to polish the laser power bed fusion additive shaped Ti6Al4V samples to study the effect of the main factors such as abrasive grain size, polishing pressure, and polishing time on the surface roughness and material-removal efficiency of the samples. With continuously decreased Al2O3 abrasive-particle size, the surface roughness initially increased and then decreased, and the material-removal rate decreased. The polishing result of 5 µm Al2O3 was better, no new scratch damage was found after 3 µm Al2O3 polishing; With increased polishing pressure from 5 N to 25 N, the deeper the abrasive particles were pressed, the greater the cutting effect and the more obvious the scratches. Surface roughness initially decreased and then increased, and the material-removal rate increased from 1.19 nm/min to 8.68 nm/min. With continuously extended polishing time, the grinding and polishing effect continued to accumulate, and the surface quality significantly improved, decreasing from 366.33 nm to 19.77 nm. These results showed that magnetorheological polishing technology was very effective in removing LPBF forming defects; the surface roughness was reduced by 96.27% and the additive defects can be completely removed.

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“…AM also has the potential to improve materials' efficiency, produce faster and more cost-effective products, save energy and emissions, and reduce intensive resource use [1]. Powder bed fusion (PBF) technology is a group of additive manufacturing (AM) technologies where an energy source is used to selectively bind or melt powder particles to build parts layer by layer to the desired geometry [2,3]. It is the most common type of technology for additive manufacturing of metallic parts for aerospace and biomedical applications [4].…”

Section: Introductionmentioning

confidence: 99%

Review of Powder Bed Fusion Additive Manufacturing for Metals

Ladani

Sadeghilaridjani

2021

Metals

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Additive manufacturing (AM) as a disruptive technology has received much attention in recent years. In practice, however, much effort is focused on the AM of polymers. It is comparatively more expensive and more challenging to additively manufacture metallic parts due to their high temperature, the cost of producing powders, and capital outlays for metal additive manufacturing equipment. The main technology currently used by numerous companies in the aerospace and biomedical sectors to fabricate metallic parts is powder bed technology, in which either electron or laser beams are used to melt and fuse the powder particles line by line to make a three-dimensional part. Since this technology is new and also sought by manufacturers, many scientific questions have arisen that need to be answered. This manuscript gives an introduction to the technology and common materials and applications. Furthermore, the microstructure and quality of parts made using powder bed technology for several materials that are commonly fabricated using this technology are reviewed and the effects of several process parameters investigated in the literature are examined. New advances in fabricating highly conductive metals such as copper and aluminum are discussed and potential for future improvements is explored.

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Opportunities and challenges in additive manufacturing of functionally graded metallic materials via powder-fed laser directed energy deposition: A review

Cited by 111 publications

References 80 publications

Phase Equilibrium and Microstructure Examinations of Eutectic Fe-C-Mn-B Alloys

Phase Equilibrium and Microstructure Examinations of Eutectic Fe-C-Mn-B Alloys

Evolution of material removal in the magnetorheological polishing of Ti6Al4V by laser power bed fusion

Review of Powder Bed Fusion Additive Manufacturing for Metals

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