Recent progress on additive manufacturing of multi-material structures with laser powder bed fusion

Wang, Di; Liu, Linqing; Deng, Guowei; Deng, Cheng; Bai, Yuchao; Yang, Yongqiang; Wu, Wei; Chen, Jie; Yang, Liu; Wang, Yonggang; Lin, Xin; Han, Changjun

doi:10.1080/17452759.2022.2028343

Cited by 165 publications

(56 citation statements)

References 117 publications

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“…LPBF as a typical additive manufacturing technology is especially suitable for the high-precision and high-efficiency manufacturing of personalized porous implants [ 25 , 26 ]. Specifically, we can use digital medical technology to conduct three-dimensional scanning of the bone defect, and then design the bone defect model through computer-aided technology.…”

Section: Discussionmentioning

confidence: 99%

Microstructure and Corrosion Behavior of Iron Based Biocomposites Prepared by Laser Additive Manufacturing

Zhou

Shuai

et al. 2022

Micromachines

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Iron (Fe) has attracted great attention as bone repair material owing to its favorable biocompatibility and mechanical properties. However, it degrades too slowly since the corrosion product layer prohibits the contact between the Fe matrix and body fluid. In this work, zinc sulfide (ZnS) was introduced into Fe bone implant manufactured using laser additive manufacturing technique. The incorporated ZnS underwent a disproportionation reaction and formed S-containing species, which was able to change the film properties including the semiconductivity, doping concentration, and film dissolution. As a result, it promoted the collapse of the passive film and accelerated the degradation rate of Fe matrix. Immersion tests proved that the Fe matrix experienced severe pitting corrosion with heavy corrosion product. Besides, the in vitro cell testing showed that Fe/ZnS possessed acceptable cell viabilities. This work indicated that Fe/ZnS biocomposite acted as a promising candidate for bone repair material.

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Section: Discussionmentioning

confidence: 99%

Microstructure and Corrosion Behavior of Iron Based Biocomposites Prepared by Laser Additive Manufacturing

Zhou

Shuai

et al. 2022

Micromachines

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“…Ti-6Al-4V alloy has been widely used in the aerospace, energy, biomedical, and automotive sectors [1,2] due to its high strength, low density, high fracture toughness, excellent corrosion resistance, and good biocompatibility [3]. Metal additive manufacturing (AM) has been advancing in the fabrication of geometrically complex metal products, typically including selective laser melting (SLM), directed energy deposition, metal binder jetting, and sheet lamination [4][5][6]. SLM has been widely applied to manufacture complex titanium parts with short lead time, great design freedom, and comparable product performance to forged counterparts [7], such as aircraft brackets [8], cervical fusion cages [9], bone implants [10], and partial denture clasps [11].…”

Section: Introductionmentioning

confidence: 99%

Densification, Tailored Microstructure, and Mechanical Properties of Selective Laser Melted Ti–6Al–4V Alloy via Annealing Heat Treatment

Wang

Chen

et al. 2022

Micromachines

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This work investigated the influence of process parameters on the densification, microstructure, and mechanical properties of a Ti–6Al–4V alloy printed by selective laser melting (SLM), followed by annealing heat treatment. In particular, the evolution mechanisms of the microstructure and mechanical properties of the printed alloy with respect to the annealing temperature near the β phase transition temperature were investigated. The process parameter optimization of SLM can lead to the densification of the printed Ti–6Al–4V alloy with a relative density of 99.51%, accompanied by an ultimate tensile strength of 1204 MPa and elongation of 7.8%. The results show that the microstructure can be tailored by altering the scanning speed and annealing temperature. The SLM-printed Ti–6Al–4V alloy contains epitaxial growth β columnar grains and internal acicular martensitic α′ grains, and the width of the β columnar grain decreases with an increase in the scanning speed. Comparatively, the printed alloy after annealing in the range of 750–1050 °C obtains the microstructure consisting of α + β dual phases. In particular, network and Widmanstätten structures are formed at the annealing temperatures of 850 °C and 1050 °C, respectively. The maximum elongation of 14% can be achieved at the annealing temperature of 950 °C, which was 79% higher than that of as-printed samples. Meanwhile, an ultimate tensile strength larger than 1000 MPa can be maintained, which still meets the application requirements of the forged Ti–6Al–4V alloy.

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“…It is challenging to manufacture the lightweight structures with an increase in geometrical complexity through traditional milling processes. Additive manufacturing (AM) has emerged as a disruptive technology that is capable of fabricating parts of complex geometries in a layer-by-layer manner and thus enabling great potential to fabricate complex parts with lightweight structures (Han et al , 2020a; Wang et al , 2022). As one of the most popular metal AM processes, laser powder bed fusion (LPBF) uses a high-energy laser beam to selectively melt metal powder on a powder bed (Han et al , 2020b).…”

Section: Introductionmentioning

confidence: 99%

Lightweight design of an AlSi10Mg aviation control stick additively manufactured by laser powder bed fusion

Wang

Wei

Liu³

et al. 2022

RPJ

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Purpose This paper aims to explore a structural optimization method to achieve the lightweight design of an aviation control stick part manufactured by laser powder bed fusion (LPBF) additive manufacturing (AM). The utilization of LPBF for the fabrication of the part provides great freedom to its structure optimization, further reduces its weight and improves its portability. Design/methodology/approach The stress distribution of the model was analyzed by finite element analysis. The material distribution path of the model was optimized through topology optimization. The structure and size of the parts were designed by applying honeycomb structures for weight reduction. The lightweight designed control stick part model was printed by LPBF using AlSi10Mg. Findings The weight of the control stick model was reduced by 32.64% through the optimization method using honeycomb structures with various geometries. The similar stress concentrations of the control stick model indicate that weight reduction has negligible effect on its mechanical strength. The maximum stress of the lightweight designed model under loading is 230.85 MPa, which is 61.81% larger than that of the original model. The lightweight control stick part manufactured by LPBF has good printability and service performance. Originality/value A structural optimization method integrating topology, shape and size optimization was proposed for a lightweight AlSi10Mg control stick printed by LPBF. The effectiveness of the optimization method, the printability of the lightweight model and the service performance of LPBF-printed AlSi10Mg control stick was verified, which provided practical references for the lightweight design of AM.

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Recent progress on additive manufacturing of multi-material structures with laser powder bed fusion

Cited by 165 publications

References 117 publications

Microstructure and Corrosion Behavior of Iron Based Biocomposites Prepared by Laser Additive Manufacturing

Microstructure and Corrosion Behavior of Iron Based Biocomposites Prepared by Laser Additive Manufacturing

Densification, Tailored Microstructure, and Mechanical Properties of Selective Laser Melted Ti–6Al–4V Alloy via Annealing Heat Treatment

Lightweight design of an AlSi10Mg aviation control stick additively manufactured by laser powder bed fusion

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