Structural integrity of additively manufactured aluminum alloys: Effects of build orientation on microstructure, porosity, and fatigue behavior

Nezhadfar, P.D.; Thompson, Spencer; Saharan, Ankit; Phan, Nam

doi:10.1016/j.addma.2021.102292

Cited by 43 publications

(30 citation statements)

References 42 publications

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“…Muhammad et al (2021) compared four different aluminum alloys, two variants of AlSi10Mg, Scalmalloy® and QuesTek Al regarding their static and dynamic mechanical properties and reported that Scalmalloy® exhibits the highest fatigue strength in the machined condition. Nezhadfar et al (2021) reported a similar study in which Scalmalloy® and four other alloys were fatigue tested, and the distribution of pores and the influence of the build orientation were analyzed. With regards to the fatigue properties of Scalmalloy®, this study revealed that specimens printed in vertical orientation show better fatigue properties than horizontal samples, which was explained with the presence and distribution of defects.…”

Section: Introductionmentioning

confidence: 99%

Fatigue properties of Scalmalloy® processed by laser powder bed fusion in as-built, chemically and conventionally machined surface condition

Raab

Bambach�

2023

Journal of Materials Processing Technology

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Section: Introductionmentioning

confidence: 99%

Fatigue properties of Scalmalloy® processed by laser powder bed fusion in as-built, chemically and conventionally machined surface condition

Raab

Bambach�

2023

Journal of Materials Processing Technology

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“…However, this sustainable practice also has the drawback of increasing the presence of satellites and surface roughness, changing the PSD and forming hydroxides and oxides [ 41 ]. The two latter cause powder degradation with a severe impact on the as-built microstructure and mechanical properties of PBF-LB/M produced parts [ 41 , 42 , 43 , 44 ]. If the issues concerning the powder morphology and PSD are the same as those related to the characterisation of virgin powders mentioned above, a separate discussion needs to be conducted on the surface chemical changes induced by powder reuse.…”

Section: Pre-processingmentioning

confidence: 99%

“…In addition, the reduced wettability could result in unmelted particles during bulk production, as illustrated in Figure 4 and observed by Read et al [ 50 ] in AlSi10Mg samples. In addition, the inhibition of the local consolidation could lead to the creation of crack formation, drastically reducing the fatigue life of the final component [ 44 ].…”

Section: Pre-processingmentioning

confidence: 99%

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

2023

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Their high strength-to-weight ratio, good corrosion resistance and excellent thermal and electrical conductivity have exponentially increased the interest in aluminium alloys in the context of laser-based powder bed fusion (PBF-LB/M) production. Although Al-based alloys are the third most investigated category of alloys in the literature and the second most used in industry, their processing by PBF-LB/M is often hampered by their considerable solidification shrinkage, tendency to oxidation, high laser reflectivity and poor powder flowability. For these reasons, high-strength Al-based alloys traditionally processed by conventional procedures have often proved to be unprintable with additive technology, so the design and development of new tailored Al-based alloys for PBF-LB/M production is necessary. The aim of the present work is to explore all the challenges encountered before, during and after the PBF-LB/M processing of Al-based alloys, in order to critically analyse the solutions proposed in the literature and suggest new approaches for addressing unsolved problems. The analysis covers the critical aspects in the literature as well as industrial needs, industrial patents published to date and possible future developments in the additive market.

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“…The build orientations of manufactured components influence the staircase adverse effect, the support density, the support area, the degree of supports required, the build time, the surface quality, mechanical strength, process design, postprocessing, and budget [ 19 , 20 , 21 , 22 , 23 ]. Several efforts by various authors were published with the goal of finding the ideal build orientation of a 3D model in order to streamline the AM process [ 24 , 25 , 26 , 27 , 28 , 29 , 30 ].…”

Section: Literature Surveymentioning

confidence: 99%

A Multi-Part Orientation Planning Schema for Fabrication of Non-Related Components Using Additive Manufacturing

et al. 2022

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Additive manufacturing (AM) is a technique that progressively deposits material in layer-by-layer manner (or in additive fashion) for producing a three-dimensional (3D) object, starting from the computer-aided design (CAD) model. This approach allows for the printing of complicated shaped objects and is quickly gaining traction in the aerospace, medical implant, jewelry, footwear, automotive, and fashion industries. AM, which was formerly used for single part customization, is currently being considered for mass customization of parts because of its positive impacts. However, part quality and build time are two main impediments to the deployment of AM for mass production. The optimal part orientation is fundamental for maximizing the part’s quality as well as being critical for reducing the fabrication time. This research provides a new method for multi-part AM production that improves quality while reducing overall build time. The automatic setup planning or orientation approach described in this paper employs two objective functions: the quality of the build component and the build time. To tackle the given problem, it introduces a three-step genetic algorithm (GA)-based solution. A feature-based technique is utilized to generate a collection of finite alternative orientations for each component within a specific part group to ensure each part’s individual build quality. Then, a GA was utilized to find the best combination of part build orientations at a global optimal level to reduce material consumption and build time. A case study of orienting nine components concurrently inside a given building chamber was provided for illustration. The findings suggest that the developed technique can increase quality, reduce support waste, and shorten overall production time. When components are positioned optimally rather than in random orientations, build time and support volume are reduced by approximately 7% and 16%, respectively.

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Structural integrity of additively manufactured aluminum alloys: Effects of build orientation on microstructure, porosity, and fatigue behavior

Cited by 43 publications

References 42 publications

Fatigue properties of Scalmalloy® processed by laser powder bed fusion in as-built, chemically and conventionally machined surface condition

Fatigue properties of Scalmalloy® processed by laser powder bed fusion in as-built, chemically and conventionally machined surface condition

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

A Multi-Part Orientation Planning Schema for Fabrication of Non-Related Components Using Additive Manufacturing

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