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Wang X, Zhang D, Li A, Yi D, Li T. A Review on Traditional Processes and Laser Powder Bed Fusion of Aluminum Alloy Microstructures, Mechanical Properties, Costs, and Applications. MATERIALS (BASEL, SWITZERLAND) 2024; 17:2553. [PMID: 38893817 PMCID: PMC11173345 DOI: 10.3390/ma17112553] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/10/2024] [Revised: 04/30/2024] [Accepted: 05/16/2024] [Indexed: 06/21/2024]
Abstract
Due to its lightweight, high strength, good machinability, and low cost, aluminum alloy has been widely used in fields such as aerospace, automotive, electronics, and construction. Traditional manufacturing processes for aluminum alloys often suffer from low material utilization, complex procedures, and long manufacturing cycles. Therefore, more and more scholars are turning their attention to the laser powder bed fusion (LPBF) process for aluminum alloys, which has the advantages of high material utilization, good formability for complex structures, and short manufacturing cycles. However, the widespread promotion and application of LPBF aluminum alloys still face challenges. The excellent printable ability, favorable mechanical performance, and low manufacturing cost are the main factors affecting the applicability of the LPBF process for aluminum alloys. This paper reviews the research status of traditional aluminum alloy processing and LPBF aluminum alloy and makes a comparison from various aspects such as microstructures, mechanical properties, application scenarios, and manufacturing costs. At present, the LPBF manufacturing cost for aluminum alloys is 2-120 times higher than that of traditional manufacturing methods, with the discrepancy depending on the complexity of the part. Therefore, it is necessary to promote the further development and application of aluminum alloy 3D printing technology from three aspects: the development of aluminum matrix composite materials reinforced with nanoceramic particles, the development of micro-alloyed aluminum alloy powders specially designed for LPBF, and the development of new technologies and equipment to reduce the manufacturing cost of LPBF aluminum alloy.
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Affiliation(s)
- Xin Wang
- Institute of Laser Engineering, School of Physics and Optoelectronic Engineering, Beijing University of Technology, Beijing 100124, China; (X.W.); (D.Y.); (T.L.)
- Beijing Engineering Research Center of 3D Printing for Digital Medical Health, Beijing 100124, China
| | - Dongyun Zhang
- Institute of Laser Engineering, School of Physics and Optoelectronic Engineering, Beijing University of Technology, Beijing 100124, China; (X.W.); (D.Y.); (T.L.)
- Beijing Engineering Research Center of 3D Printing for Digital Medical Health, Beijing 100124, China
| | - Ang Li
- China United Gas Turbine Technology Co., Ltd., Beijing 100016, China;
- School of Materials Science and Engineering, Tsinghua University, Beijing 100084, China
| | - Denghao Yi
- Institute of Laser Engineering, School of Physics and Optoelectronic Engineering, Beijing University of Technology, Beijing 100124, China; (X.W.); (D.Y.); (T.L.)
- Beijing Engineering Research Center of 3D Printing for Digital Medical Health, Beijing 100124, China
| | - Tianci Li
- Institute of Laser Engineering, School of Physics and Optoelectronic Engineering, Beijing University of Technology, Beijing 100124, China; (X.W.); (D.Y.); (T.L.)
- Beijing Engineering Research Center of 3D Printing for Digital Medical Health, Beijing 100124, China
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Alinejadian N, Wang P, Kollo L, Prashanth KG. Selective Laser Melting of Commercially Pure Molybdenum by Laser Rescanning. 3D PRINTING AND ADDITIVE MANUFACTURING 2023; 10:785-791. [PMID: 37614803 PMCID: PMC10442686 DOI: 10.1089/3dp.2021.0265] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 08/25/2023]
Abstract
Commercially pure (cp) molybdenum (Mo) is one of the high-temperature materials of immense potential. It has a body-centered cubic (bcc) structure so it is hard to fabricate using nonequilibrium processes such as the selective laser melting (SLM) without the formation of cracks due to its inherent brittleness. This study deals with the fabrication of dense and near crack-free cp-Mo samples produced by the SLM. The laser scan strategy is adjusted from a single scan to a double scan to reduce the solidification cracks. Samples produced with a laser double scan strategy show a density of ∼99% with a hardness of ∼222 HV.
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Affiliation(s)
- Navid Alinejadian
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology (TalTech), Tallinn, Estonia
| | - Pei Wang
- Additive Manufacturing Institute, Shenzhen University, Shenzhen, P.R. China
| | - Lauri Kollo
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology (TalTech), Tallinn, Estonia
| | - Konda Gokuldoss Prashanth
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology (TalTech), Tallinn, Estonia
- Erich Schmid Institute of Materials Science, Austrian Academy of Sciences, Leoben, Austria
- CBCMT, School of Mechanical Engineering, Vellore Institute of Technology, Vellore, India
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Mohanty S, Gokuldoss Prashanth K. Metallic Coatings through Additive Manufacturing: A Review. MATERIALS (BASEL, SWITZERLAND) 2023; 16:2325. [PMID: 36984204 PMCID: PMC10056185 DOI: 10.3390/ma16062325] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 01/18/2023] [Revised: 02/24/2023] [Accepted: 02/27/2023] [Indexed: 06/18/2023]
Abstract
Metallic additive manufacturing is expeditiously gaining attention in advanced industries for manufacturing intricate structures for customized applications. However, the inadequate surface quality has inspired the inception of metallic coatings through additive manufacturing methods. This work presents a brief review of the different genres of metallic coatings adapted by industries through additive manufacturing technologies. The methodologies are classified according to the type of allied energies used in the process, such as direct energy deposition, binder jetting, powder bed fusion, hot spray coatings, sheet lamination, etc. Each method is described in detail and supported by relevant literature. The paper also includes the needs, applications, and challenges involved in each process.
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Affiliation(s)
- Shalini Mohanty
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, 12818 Tallinn, Estonia
| | - Konda Gokuldoss Prashanth
- Department of Mechanical and Industrial Engineering, Tallinn University of Technology, 12818 Tallinn, Estonia
- CBCMT, School of Mechanical Engineering, Vellore Institute of Technology, Vellore 630014, Tamil Nadu, India
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Raj Mohan R, Venkatraman R, Raghuraman S, Kumar PM, Rinawa ML, Subbiah R, Arulmurugan B, Rajkumar S. Processing of Aluminium-Silicon Alloy with Metal Carbide as Reinforcement through Powder-Based Additive Manufacturing: A Critical Study. SCANNING 2022; 2022:5610333. [PMID: 35087612 PMCID: PMC8763544 DOI: 10.1155/2022/5610333] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/13/2021] [Revised: 11/07/2021] [Accepted: 12/23/2021] [Indexed: 05/05/2023]
Abstract
Powder-based additive manufacturing (PAM) is a potential fabrication approach in advancing state-of-the-art research to produce intricate components with high precision and accuracy in near-net form. In PAM, the raw materials are used in powder form, deposited on the surface layer by layer, and fused to produce the final product. PAM composite fabrication for biomedical implants, aircraft structure panels, and automotive brake rotary components is gaining popularity. In PAM composite fabrication, the aluminium cast alloy is widely preferred as a metal matrix for its unique properties, and different reinforcements are employed in the form of oxides, carbides, and nitrides. However, for enhancing the mechanical properties, the carbide form is predominantly considered. This comprehensive study focuses on contemporary research and reveals the effect of metal carbide's (MCs) addition to the aluminium matrix processed through various PAM processes, challenges involved, and potential scopes to advance the research.
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Affiliation(s)
- R. Raj Mohan
- School of Mechanical Engineering, SASTRA Deemed to be University, 613401, Thanjavur, Tamil Nadu, India
| | - R. Venkatraman
- School of Mechanical Engineering, SASTRA Deemed to be University, 613401, Thanjavur, Tamil Nadu, India
| | - S. Raghuraman
- School of Mechanical Engineering, SASTRA Deemed to be University, 613401, Thanjavur, Tamil Nadu, India
| | - P. Manoj Kumar
- Department of Mechanical Engineering, KPR Institute of Engineering and Technology, 641407, Coimbatore, Tamil Nadu, India
| | - Moti Lal Rinawa
- Department of Mechanical Engineering, Government Engineering College, 326023, Jhalawar, Rajasthan, India
| | - Ram Subbiah
- Department of Mechanical Engineering, Gokaraju Rangaraju Institute of Engineering and Technology, 500090, Hyderabad, Telangana, India
| | - B. Arulmurugan
- Department of Mechanical Engineering, KPR Institute of Engineering and Technology, 641407, Coimbatore, Tamil Nadu, India
| | - S. Rajkumar
- Department of Mechanical Engineering, Faculty of Manufacturing, Institute of Technology, Hawassa University, Ethiopia
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Effect of Substrate Plate Heating on the Microstructure and Properties of Selective Laser Melted Al-20Si-5Fe-3Cu-1Mg Alloy. MATERIALS 2021; 14:ma14020330. [PMID: 33440648 PMCID: PMC7827016 DOI: 10.3390/ma14020330] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/21/2020] [Revised: 01/06/2021] [Accepted: 01/08/2021] [Indexed: 11/24/2022]
Abstract
The Al-20Si-5Fe-3Cu-1Mg alloy was fabricated using selective laser melting (SLM). The microstructure and properties of the as-prepared SLM, post-treated SLM, and SLM with substrate plate heating are studied. The as-prepared SLM sample shows a non-uniform microstructure with four different phases: fcc-αAl, eutectic Al-Si, Al2MgSi, and δ-Al4FeSi2. With thermal treatment, the phases become coarser and the δ-Al4FeSi2 phase transforms partially to β-Al5FeSi. The sample produced with SLM substrate plate heating shows a relatively uniform microstructure without a distinct difference between hatch overlaps and track cores. Room temperature compression test results show that an as-prepared SLM sample reaches a maximum strength (862 MPa) compared to the heat-treated (524 MPa) and substrate plate heated samples (474 MPa) due to the presence of fine microstructure and the internal stresses. The reduction in strength of the sample produced with substrate plate heating is due to the coarsening of the microstructure, but the plastic deformation shows an improvement (20%). The present observations suggest that substrate plate heating can be effectively employed not only to minimize the internal stresses (by impacting the cooling rate of the process) but can also be used to modulate the mechanical properties in a controlled fashion.
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Dilution Ratio and the Resulting Composition Profile in Dissimilar Laser Powder Bed Fusion of AlSi10Mg and Al99.8. METALS 2020. [DOI: 10.3390/met10091222] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
A variant of a hybrid manufacturing process combines the benefits of laser powder bed fusion (LPBF) and conventional manufacturing. Hybrid manufacturing can result in dissimilar material combinations which are prone to process errors. This study is motivated by the future application of a hybrid manufacturing variant and focusses on dissimilar aluminium alloys were hot cracks are the dominant process errors. A theoretical model was derived for the composition profile based on the dilution ratio known from fusion welding. The theory was validated with penetration depth measurements and energy-dispersive X-ray spectroscopy line scans on samples manufactured by LPBF (powder AlSi10Mg, building platform Al99.8 and line energies Pv−1 = 0.26–0.42 J·mm−1). A material combination with a low hot crack susceptibility was chosen to establish the theory. The results suggest that the dilution ratio is dependent on the penetration depth and the layer thickness. The used line energies result in a dilution ratio of 67–86% which results in 2–6 re-melted and mixed layers per added layer. A specific process design metric, the mixture height, is proposed to estimate the spatial effect of the dilution. The results can be used to adjust process parameters to lessen the effect of process errors in dissimilar hybrid manufacturing and increase mechanical performance.
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Wojciechowski S, Talar R, Zawadzki P, Legutko S, Maruda R, Prakash C. Study on Technological Effects of a Precise Grooving of AlSi13MgCuNi Alloy with a Novel WCCo/PCD (DDCC) Inserts. MATERIALS 2020; 13:ma13112467. [PMID: 32481744 PMCID: PMC7321417 DOI: 10.3390/ma13112467] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/14/2020] [Revised: 05/22/2020] [Accepted: 05/25/2020] [Indexed: 11/28/2022]
Abstract
The WCCo/PCD (Diamond Dispersed Cemented Carbide—DDCC) manufactured with the use of PPS (pulse plasma sintering) are modern materials intended for cutting tools with the benefits of tungsten carbides and polycrystalline diamonds. Nevertheless, the cutting performance of DDCC materials are currently not recognized. Thus this study proposes the evaluation of technological effects of a precise groove turning process of hard-to-cut AlSi13MgCuNi alloy with DDCC tools. The conducted studies involved the measurements of machined surface topographies after grooving with different cutting parameters. In addition, the tool life and wear tests of DDCC inserts were conducted during grooving process and the obtained results were compiled with values reached during machining with cemented carbide tools. It was also proved that grooving of AlSi13MgCuNi alloy with DDCC inserts enables 5 times longer tool life and almost 3-fold increase of cutting path compared to values obtained during grooving with H3 and H10 cemented carbide inserts. Ultimately, the feed value of f = 0.15 mm/rev and cutting speed in a range of 800 m/min ≤ vc ≤ 1000 m/min during grooving with DDCC inserts can be defined as an optimal machining parameters, enabling the maximization of tool life and improvement in surface quality.
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Affiliation(s)
- Szymon Wojciechowski
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (R.T.); (P.Z.); (S.L.)
- Correspondence:
| | - Rafał Talar
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (R.T.); (P.Z.); (S.L.)
| | - Paweł Zawadzki
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (R.T.); (P.Z.); (S.L.)
| | - Stanisław Legutko
- Faculty of Mechanical Engineering, Poznan University of Technology, Piotrowo 3, 60-965 Poznan, Poland; (R.T.); (P.Z.); (S.L.)
| | - Radosław Maruda
- Faculty of Mechanical Engineering, University of Zielona Gora, 4 Prof. Z. Szafrana street, 65-516 Zielona Gora, Poland;
| | - Chander Prakash
- Department of Mechanical Engineering, University Institute of Engineering & Technology, Panjab University, Chandigarh 160014, India;
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Zhang Y, Guo Y, Chen Y, Cao Y, Qi H, Yang S. Microstructure and Mechanical Properties of Al-12Si Alloys Fabricated by Ultrasonic-Assisted Laser Metal Deposition. MATERIALS (BASEL, SWITZERLAND) 2019; 13:E126. [PMID: 31888072 PMCID: PMC6982305 DOI: 10.3390/ma13010126] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/25/2019] [Revised: 12/15/2019] [Accepted: 12/23/2019] [Indexed: 11/18/2022]
Abstract
This paper presents a method of ultrasonic-assisted laser metal deposition of Al-12Si alloy. The effects of the ultrasonic power and remelting treatment on the development of porosity, microstructural evolution, and tensile properties of the deposits were investigated. The results suggested that a combination of an ultrasonic vibration and remelting treatment could prolong the existence of the molten pool and the effect of the ultrasound. Therefore, the density of the samples increased from 95.4% to 99.1% compared to the as-prepared samples. The ultrasonic action in the molten pool could not only increase the density of the samples but also refine the grains and improve the tensile properties of the samples. Metallographic observation showed that the maximum size of the primary α-Al dendrites were refined from 277.5 µm to 87.5 µm. The ultimate tensile strength and elongation of the remelting treatment samples with ultrasonic vibration were ~227 ± 3 MPa and 12.2% ± 1.4%, respectively, which were approximately 1.17 and 1.53 times those of the as-prepared samples, respectively. According to the tensile properties and fracture analysis, the density increase dominated the improvement of the mechanical properties.
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Affiliation(s)
- Yang Zhang
- School of Materials Science and Engineering, Shijiazhuang Tiedao University, Shijiazhuang 050043, China
| | - Yuqi Guo
- School of Materials Science and Engineering, Shijiazhuang Tiedao University, Shijiazhuang 050043, China
| | - Yan Chen
- School of Materials Science and Engineering, Shijiazhuang Tiedao University, Shijiazhuang 050043, China
| | - Yabin Cao
- School of Materials Science and Engineering, Shijiazhuang Tiedao University, Shijiazhuang 050043, China
| | - Haibo Qi
- School of Materials Science and Engineering, Shijiazhuang Tiedao University, Shijiazhuang 050043, China
| | - Shaopu Yang
- State Key Laboratory of Mechanical Behavior and System Safety of Traffic Engineering Structures, Shijiazhuang Tiedao University, Shijiazhuang 050043, China
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Grigoriev S, Tarasova T, Gusarov A, Khmyrov R, Egorov S. Possibilities of Manufacturing Products from Cermet Compositions Using Nanoscale Powders by Additive Manufacturing Methods. MATERIALS 2019; 12:ma12203425. [PMID: 31635080 PMCID: PMC6829285 DOI: 10.3390/ma12203425] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/20/2019] [Revised: 10/14/2019] [Accepted: 10/16/2019] [Indexed: 11/16/2022]
Abstract
Complicated wear-resistant parts made by selective laser melting (SLM) of powder material based on compositions of metal and ceramics can be widely used in mining, oil engineering, and other precision engineering industries. Ceramic-metal compositions were made using nanoscale powders by powder metallurgy methods. Optimal regimes were found for the SLM method. Chemical and phase composition, fracture toughness, and wear resistance of the obtained materials were determined. The wear rate of samples from 94 wt% tungsten carbide (WC) and 6 wt% cobalt (Co) was 1.3 times lower than that of a sample from BK6 obtained by the conventional methods. The hardness of obtained samples 2500 HV was 1.6 times higher than that of a sample from BK6 obtained by the traditional method (1550 HV).
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Affiliation(s)
- Sergei Grigoriev
- Moscow State University of Technology "STANKIN", Moscow 127055, Russia.
| | - Tatiana Tarasova
- Moscow State University of Technology "STANKIN", Moscow 127055, Russia.
| | - Andrey Gusarov
- Moscow State University of Technology "STANKIN", Moscow 127055, Russia.
| | - Roman Khmyrov
- Moscow State University of Technology "STANKIN", Moscow 127055, Russia.
| | - Sergei Egorov
- Moscow State University of Technology "STANKIN", Moscow 127055, Russia.
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