Synergic strategies to improve the PBF-LB\M processability of a cracking-sensitive alloy

Martucci, Alessandra; Aversa, Alberta; Bondioli, Federica; Fino, Paolo; Lombardi, Mariangela

doi:10.1016/j.matdes.2022.111396

Cited by 14 publications

(8 citation statements)

References 42 publications

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“…The latter can be fix at 0% as recommended in Bosio et al [ 61 ] or calculated considering some geometrical on top parameters of the SST using the equation developed by Gheysen et al [ 59 ]. Although the SST approach avoids parameters that would lead to the scan track defects, it cannot fully predict phenomena associated with the layer-by-layer scanning typical of the PBF-LB/M production, as demonstrated by Martucci et al [ 62 ]. This problem is particularly evident with crack-prone Al-based alloys.…”

Section: Pre-processingmentioning

confidence: 99%

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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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Section: Pre-processingmentioning

confidence: 99%

“…Although the residual stresses can be reduced with different strategies, solving the problem of delaminations is complex and not always possible. For this reason, the most successful strategy often involves the synergetic use of all the approaches described above [ 62 ].…”

Section: During 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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“…To avoid delamination and crack formation, AlSi10Cu8Mg and AlCu20Si10Mg were processed, exploiting lower scan speed values and support structures. This approach was validated by the authors in a previous work on process optimization for crack-prone alloys [28]. A fully circular (conical and cylindrical) configuration was selected as the basic geometry of the support structures.…”

Section: Pbf-lb/m Productionmentioning

confidence: 99%

“…This reduction worsens heat diffusion during the PBF-LB/M process, consequently changing the process condition to an adequate final densification [27]. A previous work from these researchers addressed the processability via PBF-LB/M of an Al-Si-Cu-Mg alloy exceeding the copper limit of 5.65 wt% [28]. In particular, it was proved that a crack-prone AlSi10Cu8Mg alloy can also be successfully processed via PBF-LB/M with tight control of the processing parameters and the use of support structures.…”

Section: Introductionmentioning

confidence: 99%

Effect of Cu Content on the PBF-LB/M Processing of the Promising Al-Si-Cu-Mg Composition

Martucci

Bassini

Lombardi

2023

Metals

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Over the past few years, several studies have been conducted on the development of Al-Si-Cu-Mg alloys for PBF-LB/M processing. The attention gained by these systems can be attributed to their light weight and strength provided by a solid solution in the as-built state and by precipitation after heat treatment. However, published studies have kept the copper content below its solubility limit in the Al-Cu binary system under equilibrium conditions (5.65 wt%). The present study aims to explore Al-Si-Cu-Mg systems with high copper content, starting with the well-known AlSi10Cu4Mg system, moving towards AlSi10Cu8Mg, and arriving at AlCu20Si10Mg, a system never before processed with PBF-LB/M. Through the SST approach, the production of bulk samples, advanced microstructural characterization by SEM and FESEM analysis, phase identification by XRD analysis, and preliminary investigation of the mechanical properties through Vickers micro indentations, the effects of copper quantities on the processability, microstructural properties, and mechanical behavior of these compositions were investigated. The obtained results demonstrated the benefits of the supersaturated solid solution and the fine precipitation resulting from the addition of high Cu contents. In particular, the AlCu20Si10Mg system showed a very distinctive microstructure and unprecedented microhardness values.

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“…In particular, residual stress and thermal deformation represent significant issues in PBF of Ti-6Al-4V material, compromising the structural integrity of the final product [10][11][12]. These issues can emerge in the thermal properties of material, the form of thermal accumulation, defects induced by thermal deformations, dimensional inaccuracies, and layer delamination, posing considerable challenges for the successful implementation of the PBF process [13][14][15].…”

Section: Introductionmentioning

confidence: 99%

Reducing anisotropic material properties of additively manufactured Ti-6Al-4V parts via interval island laser scanning method

Yang,

Kang,

Yeon

et al. 2023

Preprint

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The Powder Bed Fusion (PBF) process using Ti-6Al-4V powder has special applications in the manufacture of high-value mechanical parts in the aerospace and medical industries. PBF is the accumulation of laser-assisted melting layers. High thermal stresses, residual stresses, and local temperature variations occur during rapid melting and cooling in processes that affect the anisotropic mechanical properties of additive manufacturing components. In this work, we analyzed the effective scanning strategy of additive manufacturing and its effect on the mechanical properties, microstructure, and residual stresses of the part. Three commonly used scanning methods to reduce the anisotropic material properties resulting from the PBF process of Ti-6Al-4V: strip, continuous island, and interval island scanning strategies are explicitly analyzed and compared. Through the cantilever experiment, it was confirmed that the interval island scan method reduces deformation by up to 12.6% compared to the conventional strip scan method due to the reduction of anisotropic residual stress.

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Synergic strategies to improve the PBF-LB\M processability of a cracking-sensitive alloy

Cited by 14 publications

References 42 publications

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

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

Effect of Cu Content on the PBF-LB/M Processing of the Promising Al-Si-Cu-Mg Composition

Reducing anisotropic material properties of additively manufactured Ti-6Al-4V parts via interval island laser scanning method

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