Review on Effects of Cyclic Thermal Input on Microstructure and Property of Materials in Laser Additive Manufacturing

doi:10.11900/0412.1961.2021.00310

Acta Metall Sin

2022, Vol. 58

Issue (10): 1221-1235 DOI: 10.11900/0412.1961.2021.00310

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Review on Effects of Cyclic Thermal Input on Microstructure and Property of Materials in Laser Additive Manufacturing

WANG Di¹, HUANG Jinhui¹, TAN Chaolin¹^,²(

), YANG Yongqiang¹

^1.School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510640, China
^2.Singapore Institute of Manufacturing Technology, A*STAR, 637662, Singapore

Cite this article:

WANG Di, HUANG Jinhui, TAN Chaolin, YANG Yongqiang. Review on Effects of Cyclic Thermal Input on Microstructure and Property of Materials in Laser Additive Manufacturing. Acta Metall Sin, 2022, 58(10): 1221-1235.

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Abstract

The unique cyclic thermal input in laser additive manufacturing (LAM) induced by layerwise deposition manner has been one of the hot research topics. This technique has shed light on the potential of using intrinsic heat treatment (IHT) to tune microstructures and enhance the mechanical performance of materials. Therefore, this article elaborates on cyclic thermal input in LAM. Herein, the influence of process parameters, deposition direction, interlayer delay time, substrate preheating, and laser remelting on cyclic thermal input was reviewed in detail. One of our key findings was that the cyclic thermal input can significantly affect the microstructures such as grain orientation, phase composition, and second phase precipitation, which in turn affects the mechanical properties of materials. The IHT effect generated by cyclic thermal input provides an opportunity for material performance enhancement and new materials development. Hence, the understanding of internal relationships among composition-process-IHT effect-microstructures-mechanical properties is critical. This is not only essential for material performance enhancement through tailoring of IHT effect but also provides enlightenment for the research and development of LAM-specific new materials based on IHT effect.

Key words: laser additive manufacturing cyclic thermal input intrinsic heat treatment anisotropy new materials development

Received: 29 July 2021

ZTFLH:

TG655

Fund: National Natural Science Foundation of China(52005189);National Key Research and Development Progrom of China(2021YFE0203500);Guangdong Province Basic and Applied Basic Research Fund Project(2019A1515110542);Guangdong Province Basic and Applied Basic Research Fund Project(2022B1515020064)

About author: TAN Chaolin, associate professor, Tel: (020)87114484, E-mail: tclscut@163.com

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	Yongqiang YANG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00310 OR https://www.ams.org.cn/EN/Y2022/V58/I10/1221

Fig.1 Schematics of the laser powder bed fusion (LPBF) system and LPBF process parameters^[4,5]

Fig.2 Schematics of the laser direct energy deposition (LDED) system component^[6,7]

Fig.3 Schematic diagram depicting the multi-scale and multi-physical processes in laser additive manufacturing (LAM) (a)^[8], and the main factors affecting the cyclic thermal input (b)

Fig.4 Schematic of the temperature field in melt pool (a)^[5], and the time-temperature histories of the deposited materials at the bottom and top (b)^[16] (IHT—intrinsic heat treatment)

Fig.5 Influence of the cyclic thermal input on mechanical properties in LAM processed materials (IDT—interlayer delay time)^[21-25]
(a) 18Ni300 (b) 316L (c) Ti6Al4V (d) H13

Fig.6 A summary of laser scan strategies (a) and the effect of laser scan strategies on crystal orientations (b)^[40]

Fig.7 Principle of in-situ precipitation strengthening and local microstructure control process^[50,51]
(a) real-time thermal history^[50]
(b) layered structure diagram^[50]
(c) secondary electron micrographs of soft and hard areas^[50]
(d) atom probe tomography (APT) analysis of the soft and hard zones^[50]
(e) microstructure with 30 s IDT^[51]
(f) microstructure with 250 s IDT^[51]

Fig.8 Schematic of residual stress generation (a), and the EBSD images showing the grain orientation of LPBF-processed Ti-45Al-2Cr-5Nb at different preheating temperatures^[55] (b) (MZ—melting zone, HAZ—heat affected zone; σ_tensile—tensile stress, σ_compressive—compressive stress, ε_thermal—thermal strain, ε_plastic—plastic strain, σ_ys—yield stress)

Fig.9 Schematic of microstructure evolution of LPBF-produced 300M steel^[62] (a), and excellent mechanical properties of AISI 420 based on in situ annealing effect^[63] (b) (A_c1—austenitzing initial isotherm, T_m—melting point, T_r—recrystallizing temperature; PAG—prior austenite grain)

Fig.10 The influence of IHT effect on microstructure (AP—as-produced, SLM—selective laser melting, LMD—laser metal deposition)^[4,16,64,65]
(a) microstructure of different layers of LDED-produced Scalmalloy samples^[16]
(b) APT analysis of Fe-19Ni-xAl^[64]
(c) radial distribution function (RDF) of titanium atoms in maraging steel^[65]
(d) nano-precipitates in LPBF-produced maraging steel^[4]

Fig.11 Perspectives on research and development (R&D) routes of LAM new approach by fully understanding and utilizing unique thermal history^[5,65,71-74] (AM—additive manufacturing, CET—columnar-to-equiaxed transition)

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