1
|
Yakubov V, Ostergaard H, Bhagavath S, Leung CLA, Hughes J, Yasa E, Khezri M, Löschke SK, Li Q, Paradowska AM. Recycled aluminium feedstock in metal additive manufacturing: A state of the art review. Heliyon 2024; 10:e27243. [PMID: 38463898 PMCID: PMC10923728 DOI: 10.1016/j.heliyon.2024.e27243] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2023] [Revised: 02/17/2024] [Accepted: 02/27/2024] [Indexed: 03/12/2024] Open
Abstract
Additive manufacturing has revolutionised the production of functional components and assemblies, offering a high degree of manufacturing flexibility. This review explores the latest advancements in additive manufacturing, focusing on its fusion-based and solid-state based technologies, and highlights the use of recycled aluminium as feedstock in these processes. The advantages and limitations of incorporating recycled materials are thoroughly analysed, considering factors such as material properties, sustainability, and process acceptance. While up to 14.4 kg CO2 per kg of aluminium is released during primary aluminium ingot production, solid-state based additive manufacturing, which is tolerant of feedstock contamination, can directly recycle aluminium. Meanwhile, fusion based additive manufacturing can readily utilise recycling pathways such as maintaining grade, upcycling, and downcycling, as well as powder reuse, providing opportunities for significant emissions reduction. The examination of feedstock manufacturing in this review, such as wire for WAAM and powder for PBF, indicates that this step indirectly increases the resource consumption of additive manufacturing. Finally, the alignment of aluminium recycling and additive manufacturing with Circular Economy principles and the UN's sustainable development goals are addressed, highlighting contributions to SDGs 3, 9, and 12.
Collapse
Affiliation(s)
- Vladislav Yakubov
- School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
| | - Halsey Ostergaard
- School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
- Australian Nuclear Science and Technology Organisation, Kirrawee, NSW, Australia
| | - Shishira Bhagavath
- Department of Mechanical Engineering, University College London, London, UK
| | - Chu Lun Alex Leung
- Department of Mechanical Engineering, University College London, London, UK
- The Research Complex at Harwell, Harwell Campus, Oxfordshire, UK
| | - James Hughes
- University of Sheffield, Advanced Manufacturing Research Centre (AMRC), Sheffield, UK
| | - Evren Yasa
- University of Sheffield, Advanced Manufacturing Research Centre (AMRC), Sheffield, UK
| | - Mani Khezri
- School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
| | - Sandra K. Löschke
- Sydney School of Architecture, Design and Planning, The University of Sydney, Sydney, NSW, Australia
| | - Qing Li
- School of Aerospace, Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW, Australia
| | - Anna M. Paradowska
- School of Civil Engineering, The University of Sydney, Sydney, NSW, Australia
- Australian Nuclear Science and Technology Organisation, Kirrawee, NSW, Australia
- School of Aerospace, Mechanical and Mechatronic Engineering, The University of Sydney, Sydney, NSW, Australia
| |
Collapse
|
2
|
Maleki E, Bagherifard S, Unal O, Revuru M, Bandini M, Guagliano M. The efficiency of tumble finishing as a final post-treatment for fatigue enhancement of notched laser powder bed fusion AlSi10Mg. Sci Rep 2023; 13:4602. [PMID: 36944692 PMCID: PMC10030593 DOI: 10.1038/s41598-023-30660-6] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/21/2022] [Accepted: 02/27/2023] [Indexed: 03/23/2023] Open
Abstract
A hybrid post-treatment combining tumble finishing as a final step after shot peening and heat treatment was developed to alleviate the adverse effects of internal and surface defects on the fatigue performance of laser powder bed fusion AlSi10Mg samples. The effects of each post-treatment were investigated individually and synergistically on microstructure, surface morphology and roughness, hardness, residual stresses, porosity, and rotating bending fatigue behavior of V-notched AlSi10Mg samples. The results reveal that tumble finishing can highly reduce surface roughness by 28 and 32% compared to the as-built and heat-treated states while inducing extra surface layer hardening and compressive residual stresses. The hybrid post-treatment of heat treatment + shot peening + tumble finishing significantly increased the fatigue life of the samples by over 500 times higher compared to the as-built series.
Collapse
Affiliation(s)
- Erfan Maleki
- Department of Mechanical Engineering, Politecnico di Milano, Milan, Italy
| | - Sara Bagherifard
- Department of Mechanical Engineering, Politecnico di Milano, Milan, Italy.
| | - Okan Unal
- Department of Mechanical Engineering, Karabuk University, Karabuk, Turkey
| | - Manoj Revuru
- Department of Mechanical Engineering, Politecnico di Milano, Milan, Italy
| | | | - Mario Guagliano
- Department of Mechanical Engineering, Politecnico di Milano, Milan, Italy
| |
Collapse
|
3
|
Additive Manufacturing of AlSi10Mg and Ti6Al4V Lightweight Alloys via Laser Powder Bed Fusion: A Review of Heat Treatments Effects. MATERIALS 2022; 15:ma15062047. [PMID: 35329496 PMCID: PMC8953129 DOI: 10.3390/ma15062047] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/03/2022] [Revised: 03/03/2022] [Accepted: 03/04/2022] [Indexed: 12/29/2022]
Abstract
Laser powder bed fusion (L-PBF) is an additive manufacturing technology that is gaining increasing interest in aerospace, automotive and biomedical applications due to the possibility of processing lightweight alloys such as AlSi10Mg and Ti6Al4V. Both these alloys have microstructures and mechanical properties that are strictly related to the type of heat treatment applied after the L-PBF process. The present review aimed to summarize the state of the art in terms of the microstructural morphology and consequent mechanical performance of these materials after different heat treatments. While optimization of the post-process heat treatment is key to obtaining excellent mechanical properties, the first requirement is to manufacture high quality and fully dense samples. Therefore, effects induced by the L-PBF process parameters and build platform temperatures were also summarized. In addition, effects induced by stress relief, annealing, solution, artificial and direct aging, hot isostatic pressing, and mixed heat treatments were reviewed for AlSi10Mg and Ti6AlV samples, highlighting variations in microstructure and corrosion resistance and consequent fracture mechanisms.
Collapse
|
4
|
Tian W, Li Z, Kang H, Cheng F, Chen F, Pang G. Passive Film Properties of Bimodal Grain Size AA7075 Aluminium Alloy Prepared by Spark Plasma Sintering. MATERIALS 2020; 13:ma13143236. [PMID: 32708110 PMCID: PMC7412012 DOI: 10.3390/ma13143236] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/05/2020] [Revised: 07/17/2020] [Accepted: 07/17/2020] [Indexed: 11/16/2022]
Abstract
The bimodal-grain-size 7075 aluminium alloys containing varied ratios of large and small 7075 aluminium powders were prepared by spark plasma sintering (SPS). The large powder was 100 ± 15 μm in diameter and the small one was 10 ± 5 μm in diameter. The 7075 aluminium alloys was completely densified under the 500 °C sintering temperature and 60 MPa pressure. The large powders constituted coarse grain zone, and the small powders constituted fine grain zone in sintered 7075 aluminium alloys. The microstructural and microchemical difference between the large and small powders was remained in coarse and fine grain zones in bulk alloys after SPS sintering, which allowed for us to investigate the effects of microstructure and microchemistry on passive properties of oxide film formed on sintered alloys. The average diameter of intermetallic phases was 201.3 nm in coarse grain zone, while its vale was 79.8 nm in fine grain zone. The alloying element content in intermetallic phases in coarse grain zone was 33% to 48% higher than that on fine grain zone. The alloying element depletion zone surrounding intermetallic phases in coarse grain zone showed a bigger width and a more severe element depletion. The coarse grain zone in alloys showed a bigger electrochemical heterogeneity as compared to fine grain zone. The passive film formed on coarse grain zone had a thicker thickness and a point defect density of 2.4 × 1024 m−3, and the film on fine grain zone had a thinner thickness and a point defect density of 4.0 × 1023 m−3. The film resistance was 3.25 × 105 Ωcm2 on coarse grain zone, while it was 6.46 × 105 Ωcm2 on fine grain zone. The passive potential range of sintered alloys increased from 457 mV to 678 mV, while the corrosion current density decreased from 8.59 × 10−7 A/cm2 to 6.78 × 10−7 A/cm2 as fine grain zone increasing from 0% to 100%, which implied that the corrosion resistance of alloys increased with the increasing content of fine grains. The passive film on coarse grain zone exhibited bigger corrosion cavities after pitting initiation compared to that on fine grain zone. The passive film formed on fine grain zone showed a better corrosion resistance. The protectiveness of passive film was mainly determined by defect density rather than the thickness in this work.
Collapse
Affiliation(s)
- Wenming Tian
- School of Materials Engineering, North China Institute of Aerospace Engineering, No.133 Aimindong Road, Langfang 065000, China; (Z.L.); (H.K.); (F.C.); (G.P.)
- Heibei Key Laboratory of Trans-Media Aerial Underwater Vehicle, North China Institute of Aerospace Engineering, No.133 Aimindong Road, Langfang 065000, China
- Correspondence: ; Tel.: +86-181-3169-1636
| | - Zhonglei Li
- School of Materials Engineering, North China Institute of Aerospace Engineering, No.133 Aimindong Road, Langfang 065000, China; (Z.L.); (H.K.); (F.C.); (G.P.)
- Heibei Key Laboratory of Trans-Media Aerial Underwater Vehicle, North China Institute of Aerospace Engineering, No.133 Aimindong Road, Langfang 065000, China
| | - HuiFeng Kang
- School of Materials Engineering, North China Institute of Aerospace Engineering, No.133 Aimindong Road, Langfang 065000, China; (Z.L.); (H.K.); (F.C.); (G.P.)
- Heibei Key Laboratory of Trans-Media Aerial Underwater Vehicle, North China Institute of Aerospace Engineering, No.133 Aimindong Road, Langfang 065000, China
| | - Fasong Cheng
- Aero Engine Corporation of China (AECC) Guizhou Liyang Aviation Power CO., LTD., Guiyang 550014, China;
| | - Fangfang Chen
- School of Materials Engineering, North China Institute of Aerospace Engineering, No.133 Aimindong Road, Langfang 065000, China; (Z.L.); (H.K.); (F.C.); (G.P.)
| | - Guoxing Pang
- School of Materials Engineering, North China Institute of Aerospace Engineering, No.133 Aimindong Road, Langfang 065000, China; (Z.L.); (H.K.); (F.C.); (G.P.)
| |
Collapse
|
5
|
Liu X, Sekizawa K, Suzuki A, Takata N, Kobashi M, Yamada T. Compressive Properties of Al-Si Alloy Lattice Structures with Three Different Unit Cells Fabricated via Laser Powder Bed Fusion. MATERIALS 2020; 13:ma13132902. [PMID: 32605236 PMCID: PMC7372452 DOI: 10.3390/ma13132902] [Citation(s) in RCA: 17] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/10/2020] [Revised: 06/23/2020] [Accepted: 06/25/2020] [Indexed: 11/16/2022]
Abstract
In the present study, in order to elucidate geometrical features dominating deformation behaviors and their associated compressive properties of lattice structures, AlSi10Mg lattice structures with three different unit cells were fabricated by laser powder bed fusion. Compressive properties were examined by compression and indentation tests, micro X-ray computed tomography (CT), together with finite element analysis. The truncated octahedron- unit cell (TO) lattice structures exhibited highest stiffness and plateau stress among the studied lattice structures. The body centered cubic-unit cell (BCC) and TO lattice structures experienced the formation of shear bands with stress drops, while the hexagon-unit cell (Hexa) lattice structure behaved in a continuous deformation and flat plateau region. The Hexa lattice structure densified at a smaller strain than the BCC and TO lattice structures, due to high density of the struts in the compressive direction. Static and high-speed indentation tests revealed that the TO and Hexa exhibited slight strain rate dependence of the compressive strength, whereas the BCC lattice structure showed a large strain rate dependence. Among the lattice structures in the present study, the TO lattice exhibited the highest energy absorption capacity comparable to previously reported titanium alloy lattice structures.
Collapse
Affiliation(s)
- Xiaoyang Liu
- Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, Japan; (K.S.); (A.S.); (N.T.); (M.K.)
- Correspondence:
| | - Keito Sekizawa
- Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, Japan; (K.S.); (A.S.); (N.T.); (M.K.)
| | - Asuka Suzuki
- Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, Japan; (K.S.); (A.S.); (N.T.); (M.K.)
| | - Naoki Takata
- Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, Japan; (K.S.); (A.S.); (N.T.); (M.K.)
| | - Makoto Kobashi
- Department of Materials Process Engineering, Graduate School of Engineering, Nagoya University, Furo-cho, Chikusa-ku, Nagoya 464-8603, Japan; (K.S.); (A.S.); (N.T.); (M.K.)
| | - Tetsuya Yamada
- Department of Space Flight Systems, JAXA (Japan Aerospace Exploration Agency), ISAS (Institute of Space and Astronautical Science), Yoshinodai, Chuo-ku, Sagamihara 252-5210, Japan;
| |
Collapse
|