Post-processing heat treatment of lightweight magnesium alloys fabricated by additive manufacturing: a review

Motallebi, Reza; Savaedi, Zeinab; Mirzadeh, Hamed

doi:10.1016/j.jmrt.2022.07.154

Cited by 54 publications

(7 citation statements)

References 91 publications

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“…Although traditional post-processing improves surface quality, conventional methods are not suitable for complex structures, especially for difficult-to-cut materials [ 28 ], thus, both the subtractive and transformative manufacturing technologies are combined with AM for improvement of part quality and process performance [ 168 ]. Therefore, the concept of hybridization [ 169 ] goes beyond post-processing, as illustrated in Figure 17 a [ 36 ], where the hybrid-AM processes are usually cyclic processes involving synergy between both techniques, and are distinguished from postprocessing operations. Figure 17 b shows the division of groups according to the primary additive technique [ 69 ] of PBF-based processes (directed to produce complex whole parts) and DED processes (focused on the generation of coatings).…”

Section: Intelligence In State-of-the-art Manufacturing Technology: M...mentioning

confidence: 99%

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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Additive manufacturing (AM), an enabler of Industry 4.0, recently opened limitless possibilities in various sectors covering personal, industrial, medical, aviation and even extra-terrestrial applications. Although significant research thrust is prevalent on this topic, a detailed review covering the impact, status, and prospects of artificial intelligence (AI) in the manufacturing sector has been ignored in the literature. Therefore, this review provides comprehensive information on smart mechanisms and systems emphasizing additive, subtractive and/or hybrid manufacturing processes in a collaborative, predictive, decisive, and intelligent environment. Relevant electronic databases were searched, and 248 articles were selected for qualitative synthesis. Our review suggests that significant improvements are required in connectivity, data sensing, and collection to enhance both subtractive and additive technologies, though the pervasive use of AI by machines and software helps to automate processes. An intelligent system is highly recommended in both conventional and non-conventional subtractive manufacturing (SM) methods to monitor and inspect the workpiece conditions for defect detection and to control the machining strategies in response to instantaneous output. Similarly, AM product quality can be improved through the online monitoring of melt pool and defect formation using suitable sensing devices followed by process control using machine learning (ML) algorithms. Challenges in implementing intelligent additive and subtractive manufacturing systems are also discussed in the article. The challenges comprise difficulty in self-optimizing CNC systems considering real-time material property and tool condition, defect detections by in-situ AM process monitoring, issues of overfitting and underfitting data in ML models and expensive and complicated set-ups in hybrid manufacturing processes.

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Section: Intelligence In State-of-the-art Manufacturing Technology: M...mentioning

confidence: 99%

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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“…Coming to the LPBF approach, Pawlak et al investigated the fabrication of AZ31 alloy-based material parts via the LPBF approach and attributed it to the low porosity level of around 0.5% [93]. In LPBF, AZ61 and AZ91 also attain such a low porosity level, proving the alloy's acceptable printability [27,94]. The AZ91 and AZ61 alloys forming through the LPBF approach attributed to equiaxed and fine grain distribution, as well as attaining the texture that was almost randomly distributed [95][96][97][98].…”

Section: Mg-al Alloymentioning

confidence: 99%

Advancements in the Additive Manufacturing of Magnesium and Aluminum Alloys through Laser-Based Approach

et al. 2022

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Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives such as reduced part numbers, greater functionality, and lightweight, among others. Polymers, metals, and ceramics are the few materials that can be used in AM technology, but metallic materials (Magnesium and Aluminum) are attracting more attention from the research and industrial point of view. Understanding the role processing parameters of laser-based additive manufacturing is critical to maximize the usage of material in forming the product geometry. LPBF (Laser powder-based fusion) method is regarded as a potent and effective additive manufacturing technique for creating intricate 3D forms/parts with high levels of precision and reproducibility together with acceptable metallurgical characteristics. While dealing with LBPF, some degree of porosity is acceptable because it is unavoidable; hot ripping and cracking must be avoided, though. The necessary manufacturing of pre-alloyed powder and ductility remains to be the primary concern while dealing with a laser-based additive manufacturing approach. The presence of the Al-Si eutectic phase in AlSi10Mg and AlSi12 alloy attributing to excellent castability and low shrinkage, attaining the most attention in the laser-based approach. Related studies with these alloys along with precipitation hardening and heat treatment processing were discussed. The Pure Mg, Mg-Al alloy, Mg-RE alloy, and Mg-Zn alloy along with the mechanical characteristics, electrochemical durability, and biocompatibility of Mg-based material have been elaborated in the work-study. The review article also summarizes the processing parameters of the additive manufacturing powder-based approach relating to different Mg-based alloys. For future aspects, the optimization of processing parameters, composition of the alloy, and quality of powder material used will significantly improve the ductility of additively manufactured Mg alloy by the LPBF approach. Other than that, the recycling of Mg-alloy powder hasn’t been investigated yet. Meanwhile, the post-processing approach, including a homogeneous coating on the porous scaffolds, will mark the suitability in terms of future advancements in Mg and Al-based alloys.

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“…Coming to the LPBF approach, Pawlak et al investigated the fabrication of AZ31 alloy-based material parts via LPBF approach and attributed to the low porosity level around 0.5% [93]. In LPBF, AZ61 and AZ91 also attain such a low porosity level, proving the alloy's acceptable printability [27,94]. The AZ91 and AZ61 alloys forming through LPBF approach attributed to equiaxed and fine grain distribution, as well as attaining the texture that was almost randomly distributed [95][96][97][98].…”

Section: Mg-al Alloymentioning

confidence: 99%

Advancement of Magnesium and Aluminum Alloys in the Role of Additive Manufacturing

Sharma¹,

Grewal²,

Saxena³

et al. 2022

Preprint

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Magnesium and Aluminum alloys continue to be important in the context of modern and lightweight technologies. With the advancement of additive manufacturing (AM), components can be produced directly in a net shape, widen up the usage of magnesium and aluminum alloys as well as holding new ideas for the application of unique physical structures made feasible by 3D printing. Laser-based approach, one of the metal additive manufacturing (AM) methods, enables the formation of arbitrary 3D structures. With promising findings, research in this area is advancing quickly, bringing up a variety of potential applications in both the scientific and industrial sectors. Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives like reduced part numbers, greater functionality, and lightweight, among others. AM has the ability to meet demands by lowering costs and speeding up the manufacturing process. Due to their popularity in numerous high-value applications, aluminum, and magnesium alloys are one of the key material systems being researched in the laser-based additive manufacturing approaches. The review here aims to comprehensively examine the additive manufacturing of magnesium and aluminum alloys, highlighting the influence of the laser-based additive manufacturing approach on the mechanical characteristics, microstructure, and tribological performance of magnesium and aluminum alloys.

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Post-processing heat treatment of lightweight magnesium alloys fabricated by additive manufacturing: a review

Cited by 54 publications

References 91 publications

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

Advancements in the Additive Manufacturing of Magnesium and Aluminum Alloys through Laser-Based Approach

Advancement of Magnesium and Aluminum Alloys in the Role of Additive Manufacturing

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