Additive manufacturing of metals: Microstructure evolution and multistage control

•A comprehensive processing map is proposed for additive manufacturing of metals.•Additively manufactured microstructures are developed during and after solidification of melt pool.•Formation mechanisms of multistage microstructures are analyzed, accordingly the microstructure control methods are pr...

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Published in	Journal of materials science & technology Vol. 100; pp. 224 - 236
Main Authors	Liu, Zhiyuan, Zhao, Dandan, Wang, Pei, Yan, Ming, Yang, Can, Chen, Zhangwei, Lu, Jian, Lu, Zhaoping
Format	Journal Article
Language	English
Published	Elsevier Ltd 20.02.2022
Subjects	Additive manufacturing Melt pool Metallic materials Microstructure evolution Processing map Processing map Melt pool Additive manufacturing Metallic materials Microstructure evolution
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Abstract	•A comprehensive processing map is proposed for additive manufacturing of metals.•Additively manufactured microstructures are developed during and after solidification of melt pool.•Formation mechanisms of multistage microstructures are analyzed, accordingly the microstructure control methods are proposed. As a revolutionary industrial technology, additive manufacturing creates objects by adding materials layer by layer and hence can fabricate customized components with an unprecedented degree of freedom. For metallic materials, unique hierarchical microstructures are constructed during additive manufacturing, which endow them with numerous excellent properties. To take full advantage of additive manufacturing, an in-depth understanding of the microstructure evolution mechanism is required. To this end, this review explores the fundamental procedures of additive manufacturing, that is, the formation and binding of melt pools. A comprehensive processing map is proposed that integrates melt pool energy- and geometry-related process parameters together. Based on it, additively manufactured microstructures are developed during and after the solidification of constituent melt pool. The solidification structures are composed of primary columnar grains and fine secondary phases that form along the grain boundaries. The post-solidification structures include submicron scale dislocation cells stemming from internal residual stress and nanoscale precipitates induced by intrinsic heat treatment during cyclic heating of adjacent melt pool. Based on solidification and dislocation theories, the formation mechanisms of the multistage microstructures are thoroughly analyzed, and accordingly, multistage control methods are proposed. In addition, the underlying atomic scale structural features are briefly discussed. Furthermore, microstructure design for additive manufacturing through adjustment of process parameters and alloy composition is addressed to fulfill the great potential of the technique. This review not only builds a solid microstructural framework for metallic materials produced by additive manufacturing but also provides a promising guideline to adjust their mechanical properties. [Display omitted]
AbstractList	•A comprehensive processing map is proposed for additive manufacturing of metals.•Additively manufactured microstructures are developed during and after solidification of melt pool.•Formation mechanisms of multistage microstructures are analyzed, accordingly the microstructure control methods are proposed. As a revolutionary industrial technology, additive manufacturing creates objects by adding materials layer by layer and hence can fabricate customized components with an unprecedented degree of freedom. For metallic materials, unique hierarchical microstructures are constructed during additive manufacturing, which endow them with numerous excellent properties. To take full advantage of additive manufacturing, an in-depth understanding of the microstructure evolution mechanism is required. To this end, this review explores the fundamental procedures of additive manufacturing, that is, the formation and binding of melt pools. A comprehensive processing map is proposed that integrates melt pool energy- and geometry-related process parameters together. Based on it, additively manufactured microstructures are developed during and after the solidification of constituent melt pool. The solidification structures are composed of primary columnar grains and fine secondary phases that form along the grain boundaries. The post-solidification structures include submicron scale dislocation cells stemming from internal residual stress and nanoscale precipitates induced by intrinsic heat treatment during cyclic heating of adjacent melt pool. Based on solidification and dislocation theories, the formation mechanisms of the multistage microstructures are thoroughly analyzed, and accordingly, multistage control methods are proposed. In addition, the underlying atomic scale structural features are briefly discussed. Furthermore, microstructure design for additive manufacturing through adjustment of process parameters and alloy composition is addressed to fulfill the great potential of the technique. This review not only builds a solid microstructural framework for metallic materials produced by additive manufacturing but also provides a promising guideline to adjust their mechanical properties. [Display omitted]
Author	Yang, Can Lu, Zhaoping Chen, Zhangwei Lu, Jian Liu, Zhiyuan Yan, Ming Zhao, Dandan Wang, Pei
Author_xml	– sequence: 1 givenname: Zhiyuan surname: Liu fullname: Liu, Zhiyuan email: zyliu@szu.edu.cn organization: Additive Manufacturing Institute, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China – sequence: 2 givenname: Dandan surname: Zhao fullname: Zhao, Dandan organization: Additive Manufacturing Institute, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China – sequence: 3 givenname: Pei surname: Wang fullname: Wang, Pei organization: Additive Manufacturing Institute, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China – sequence: 4 givenname: Ming surname: Yan fullname: Yan, Ming organization: Department of Materials Science and Engineering, Southern University of Science and Technology, Shenzhen 518055, China – sequence: 5 givenname: Can surname: Yang fullname: Yang, Can organization: Sino-German College of Intelligent Manufacturing, Shenzhen Technology University, Shenzhen 518118, China – sequence: 6 givenname: Zhangwei surname: Chen fullname: Chen, Zhangwei organization: Additive Manufacturing Institute, College of Mechatronics and Control Engineering, Shenzhen University, Shenzhen 518060, China – sequence: 7 givenname: Jian surname: Lu fullname: Lu, Jian organization: CityU-Shenzhen Futian Research Institute, Shenzhen 518045, China – sequence: 8 givenname: Zhaoping surname: Lu fullname: Lu, Zhaoping organization: Beijing Advanced Innovation Center for Materials Genome Engineering, State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing 100083, China
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Snippet	•A comprehensive processing map is proposed for additive manufacturing of metals.•Additively manufactured microstructures are developed during and after...
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SubjectTerms	Additive manufacturing Melt pool Metallic materials Microstructure evolution Processing map
Title	Additive manufacturing of metals: Microstructure evolution and multistage control
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