Alloy design for laser powder bed fusion additive manufacturing: a critical review
Metal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM have persisted. These chall...
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| Abstract | Metal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM have persisted. These challenges arise because commercial alloys are primarily designed for conventional casting or forging processes, overlooking the fast cooling rates, steep temperature gradients and multiple thermal cycles of L-PBF. To address this, there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies. This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF. It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing alloys. The review begins by discussing the features of the L-PBF processes, focusing on rapid solidification and intrinsic heat treatment. Next, the printability of the four main existing alloys (Fe-, Ni-, Al- and Ti-based alloys) is critically assessed, with a comparison of their conventional weldability. It was found that the weldability criteria are not always applicable in estimating printability. Furthermore, the review presents recent advances in alloy development and associated strategies, categorizing them into crack mitigation-oriented, microstructure manipulation-oriented and machine learning-assisted approaches. Lastly, an outlook and suggestions are given to highlight the issues that need to be addressed in future work.
Process features and typical defects of L-PBF are summarized.
Printability of Fe-based, Ni-based, Al-based and Ti-based alloys is summarized and discussed.
The application of weldability criteria in assessing printability during L-PBF for each alloy is evaluated.
Strategies used in alloy design for L-PBF are summarized and categorized into crack mitigation-oriented, microstructure manipulation-oriented and machine learning-assisted approaches. |
|---|---|
| AbstractList | Metal additive manufacturing(AM)has been extensively studied in recent decades.Despite the significant progress achieved in manufacturing complex shapes and structures,challenges such as severe cracking when using existing alloys for laser powder bed fusion(L-PBF)AM have persisted.These challenges arise because commercial alloys are primarily designed for conventional casting or forging processes,overlooking the fast cooling rates,steep temperature gradients and multiple thermal cycles of L-PBF.To address this,there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies.This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF.It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing alloys.The review begins by discussing the features of the L-PBF processes,focusing on rapid solidification and intrinsic heat treatment.Next,the printability of the four main existing alloys(Fe-,Ni-,Al-and Ti-based alloys)is critically assessed,with a comparison of their conventional weldability.It was found that the weldability criteria are not always applicable in estimating printability.Furthermore,the review presents recent advances in alloy development and associated strategies,categorizing them into crack mitigation-oriented,microstructure manipulation-oriented and machine learning-assisted approaches.Lastly,an outlook and suggestions are given to highlight the issues that need to be addressed in future work. Metal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM have persisted. These challenges arise because commercial alloys are primarily designed for conventional casting or forging processes, overlooking the fast cooling rates, steep temperature gradients and multiple thermal cycles of L-PBF. To address this, there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies. This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF. It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing alloys. The review begins by discussing the features of the L-PBF processes, focusing on rapid solidification and intrinsic heat treatment. Next, the printability of the four main existing alloys (Fe-, Ni-, Al- and Ti-based alloys) is critically assessed, with a comparison of their conventional weldability. It was found that the weldability criteria are not always applicable in estimating printability. Furthermore, the review presents recent advances in alloy development and associated strategies, categorizing them into crack mitigation-oriented, microstructure manipulation-oriented and machine learning-assisted approaches. Lastly, an outlook and suggestions are given to highlight the issues that need to be addressed in future work. Process features and typical defects of L-PBF are summarized. Printability of Fe-based, Ni-based, Al-based and Ti-based alloys is summarized and discussed. The application of weldability criteria in assessing printability during L-PBF for each alloy is evaluated. Strategies used in alloy design for L-PBF are summarized and categorized into crack mitigation-oriented, microstructure manipulation-oriented and machine learning-assisted approaches. |
| Author | Wang, Xiebin Liu, Zhuangzhuang Zhou, Qihang Li, Guichuan Vanmeensel, Kim Xie, Jianxin Liang, Xiaokang |
| AuthorAffiliation | Key Laboratory for Advanced Materials Processing(MOE),Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China;Beijing Advanced Innovation Center for Materials Genome Engineering,University of Science and Technology Beijing,Beijing 100083,People's Republic of China;Beijing Laboratory of Metallic Materials and Processing for Modern Transportation,Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China%Key Laboratory for Advanced Materials Processing(MOE),Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China%Capital Aerospace Machinery Corporation Limited,Beijing 100076,People's Republic of China%Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials(Ministry of Education),Shandong University,Jingshi Road 17923,Jinan 250061,Peop |
| AuthorAffiliation_xml | – name: Key Laboratory for Advanced Materials Processing(MOE),Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China;Beijing Advanced Innovation Center for Materials Genome Engineering,University of Science and Technology Beijing,Beijing 100083,People's Republic of China;Beijing Laboratory of Metallic Materials and Processing for Modern Transportation,Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China%Key Laboratory for Advanced Materials Processing(MOE),Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China%Capital Aerospace Machinery Corporation Limited,Beijing 100076,People's Republic of China%Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials(Ministry of Education),Shandong University,Jingshi Road 17923,Jinan 250061,People's Republic of China%Department of Materials Engineering,KU Leuven,Leuven 3001,Belgium |
| Author_xml | – sequence: 1 givenname: Zhuangzhuang orcidid: 0000-0002-9732-7338 surname: Liu fullname: Liu, Zhuangzhuang organization: Beijing Laboratory of Metallic Materials and Processing for Modern Transportation, Institute for Advanced Materials and Technology, University of Science and Technology Beijing , Beijing 100083, People’s Republic of China – sequence: 2 givenname: Qihang surname: Zhou fullname: Zhou, Qihang organization: Key Laboratory for Advanced Materials Processing (MOE), Institute for Advanced Materials and Technology, University of Science and Technology Beijing , Beijing 100083, People’s Republic of China – sequence: 3 givenname: Xiaokang surname: Liang fullname: Liang, Xiaokang organization: Capital Aerospace Machinery Corporation Limited , Beijing 100076, People’s Republic of China – sequence: 4 givenname: Xiebin orcidid: 0000-0001-5132-6797 surname: Wang fullname: Wang, Xiebin organization: Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University , Jingshi Road 17923, Jinan 250061, People’s Republic of China – sequence: 5 givenname: Guichuan surname: Li fullname: Li, Guichuan organization: KU Leuven Department of Materials Engineering, Leuven 3001, Belgium – sequence: 6 givenname: Kim surname: Vanmeensel fullname: Vanmeensel, Kim organization: KU Leuven Department of Materials Engineering, Leuven 3001, Belgium – sequence: 7 givenname: Jianxin surname: Xie fullname: Xie, Jianxin organization: Beijing Laboratory of Metallic Materials and Processing for Modern Transportation, Institute for Advanced Materials and Technology, University of Science and Technology Beijing , Beijing 100083, People’s Republic of China |
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| Keywords | alloy design crack mitigation printability laser powder bed fusion |
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| PublicationTitle_FL | International Journal of Extreme Manufacturing |
| PublicationYear | 2024 |
| Publisher | IOP Publishing Beijing Advanced Innovation Center for Materials Genome Engineering,University of Science and Technology Beijing,Beijing 100083,People's Republic of China Key Laboratory for Advanced Materials Processing(MOE),Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China Beijing Laboratory of Metallic Materials and Processing for Modern Transportation,Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China%Key Laboratory for Advanced Materials Processing(MOE),Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China%Capital Aerospace Machinery Corporation Limited,Beijing 100076,People's Republic of China%Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials(Ministry of Education),Shandong University,Jingshi Road 17923,Jinan 250061,People's Republic of China%Department of Materials Engineering,KU Leuven,Leuven 3001,Belgium |
| Publisher_xml | – name: IOP Publishing – name: Key Laboratory for Advanced Materials Processing(MOE),Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China – name: Beijing Advanced Innovation Center for Materials Genome Engineering,University of Science and Technology Beijing,Beijing 100083,People's Republic of China – name: Beijing Laboratory of Metallic Materials and Processing for Modern Transportation,Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China%Key Laboratory for Advanced Materials Processing(MOE),Institute for Advanced Materials and Technology,University of Science and Technology Beijing,Beijing 100083,People's Republic of China%Capital Aerospace Machinery Corporation Limited,Beijing 100076,People's Republic of China%Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials(Ministry of Education),Shandong University,Jingshi Road 17923,Jinan 250061,People's Republic of China%Department of Materials Engineering,KU Leuven,Leuven 3001,Belgium |
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| SubjectTerms | Additive manufacturing alloy design Alloy development Alloy powders Alloys Cooling rate crack mitigation Heat treating Heat treatment Iron Laser beam welding laser powder bed fusion Machine learning Manufacturing Powder beds printability Rapid solidification Titanium base alloys Weldability |
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| Title | Alloy design for laser powder bed fusion additive manufacturing: a critical review |
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