Review on residual stress in selective laser melting additive manufacturing of alloy parts

Fang, Ze-Chen; Wu, Zhongliang; Huang, Chenguang; Wu, Chung‐Chih

doi:10.1016/j.optlastec.2020.106283

Cited by 198 publications

(57 citation statements)

References 171 publications

(259 reference statements)

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“…Another technological advantage is the ability to produce parts with an almost final shape, thus reducing production time and costs [ 6 ]. Nevertheless, products obtained by AM still require further development on open issues regarding internal defects due to printing errors and residual and thermal stresses, for instance [ 7 , 8 ]. This quality uncertainty can create parts wastage, increase parts delivery time and prevent AM implementation in industries that require high performance components with quality assurance.…”

Section: Introductionmentioning

confidence: 99%

In Situ Monitoring of Additive Manufacturing Using Digital Image Correlation: A Review

2021

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This paper is a critical review of in situ full-field measurements provided by digital image correlation (DIC) for inspecting and enhancing additive manufacturing (AM) processes. The principle of DIC is firstly recalled and its applicability during different AM processes systematically addressed. Relevant customisations of DIC in AM processes are highlighted regarding optical system, lighting and speckled pattern procedures. A perspective is given in view of the impact of in situ monitoring regarding AM processes based on target subjects concerning defect characterisation, evaluation of residual stresses, geometric distortions, strain measurements, numerical modelling validation and material characterisation. Finally, a case study on in situ measurements with DIC for wire and arc additive manufacturing (WAAM) is presented emphasizing opportunities, challenges and solutions.

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Section: Introductionmentioning

confidence: 99%

In Situ Monitoring of Additive Manufacturing Using Digital Image Correlation: A Review

2021

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“…1 Because of its important applications in aerospace, automobile manufacturing, biomedical science, and so on, it has been one of the most promising and powerful technologies. [2][3][4] The AM technologies used for Ti6Al4V include selective electron beam melting, 5 direct metal deposition, 6 and selective laser melting (SLM). 7 SLM is one of the most commonly used methods in AM; it is a rapid melting and cooling solidification technology of metal powders under the action of a high energy laser beam.…”

Section: Introductionmentioning

confidence: 99%

“…During this process, residual stress also emerges at the same time, which can lead to deformation, cracking, and destroying the mechanical property of the parts. [30][31][32] Therefore, it is necessary to postprocess the AM-fabricated Ti6Al4V alloy before using.…”

Section: Introductionmentioning

confidence: 99%

Laser polishing of additive manufactured Ti6Al4V alloy: a review

Zuo

2021

Opt. Eng.

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Additive manufactured Ti6Al4V alloy has excellent comprehensive properties and has broad application prospects in the aerospace, biomedicine, and other fields. However, the fabricated components are too rough to use directly. So, a corresponding postprocess is needed urgently. The conventional finishing process cannot meet the requirements of green and efficient processing because of its time consumption, environmental pollution, and low productivity. Laser polishing, as a highly efficient and noncontact post-treatment technology, has attracted more and more attention in the polishing of additive manufactured Ti6Al4V alloy. The research of laser polishing of Ti6Al4V alloy in recent years has expatiated and includes laser polishing mechanisms, surface roughness and morphology, microstructure, mechanical properties, and finite element simulation analysis during laser polishing. Furthermore, the existing challenges of laser-polished Ti6Al4V alloy are summarized, and future development directions are proposed.

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“…As a new manufacturing technology integrating laser, digitization, materials science, and other disciplines, LAM has obtained widespread attention in recent years since it can realize dimension reduction manufacturing, complex forming, and high material utilization [ 22 , 23 , 24 ]. According to material feed-in methods, LAM can be divided into powder spreading type selective laser melting [ 25 ] and powder feeding type laser melting deposition [ 10 , 11 , 26 ]. Laser melting deposition technology is also called laser cladding (LC), which uses a high-power laser to melt powder and/or wire, and substrate together to obtain a cladding layer with good metallurgical bonding performance [ 2 , 27 ].…”

Section: Introductionmentioning

confidence: 99%

Microstructure and Wear Resistance of Multi-Layer Ni-Based Alloy Cladding Coating on 316L SS under Different Laser Power

Dai

Guo

et al. 2021

Materials

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We prepared three kinds of Ni based alloy cladding coatings on 316L stainless steel at different power levels. The microstructure of the cladding layer was observed and analyzed by XRD, metallographic microscope, and SEM. The hardness of the cladding layer was measured, and the wear resistance of it was tested by a friction instrument. The results show that the effect of laser cladding is good, and it has good metallurgical bonding with the substrate. Different microstructures such as dendritic and equiaxed grains can be observed in the cladding layer. With the increase in laser power, more equiaxed and columnar dendrites can be observed. The phase composition of the cladding layer is mainly composed of γ–Ni solid solution and some intermetallic compounds such as Ni3B, Cr5B3, and Ni17Si3. The results of EDS show that there are some differences in the distribution of C and Si between dendrites. The hardness of the cladding layer is about 600 HV0.2, which is about three times of the substrate (~200 HV0.2). Through the analysis of the wear morphology, the substrate wear is serious, there are serious shedding, mainly adhesive wear, and abrasive wear. However, the wear of the cladding layer is slight, which is abrasive wear, and there are some grooves on the surface.

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Review on residual stress in selective laser melting additive manufacturing of alloy parts

Abstract: The research on residual stress arising in additive manufacturing by SLM are reviewed.• The advantages and disadvantages of mainstream research methods are analyzed.• New concepts on controlling the residual stress in alloy parts by SLM are proposed.

Cited by 198 publications

References 171 publications

In Situ Monitoring of Additive Manufacturing Using Digital Image Correlation: A Review

In Situ Monitoring of Additive Manufacturing Using Digital Image Correlation: A Review

Laser polishing of additive manufactured Ti6Al4V alloy: a review

Microstructure and Wear Resistance of Multi-Layer Ni-Based Alloy Cladding Coating on 316L SS under Different Laser Power

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