Additive Manufacturing of Magnesium Alloys by Selective Laser Melting Technology: A Review

doi:10.11900/0412.1961.2022.00166

Acta Metall Sin

2023, Vol. 59

Issue (1): 31-54 DOI: 10.11900/0412.1961.2022.00166

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Additive Manufacturing of Magnesium Alloys by Selective Laser Melting Technology: A Review

PENG Liming¹^,², DENG Qingchen¹^,²(

), WU Yujuan¹^,², FU Penghuai¹^,², LIU Ziyi¹^,², WU Qianye¹^,², CHEN Kai¹^,², DING Wenjiang¹^,²

1.National Engineering Research Center of Light Alloys Net Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
2.State Key Laboratory of Metal Matrix Composites, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China

Cite this article:

PENG Liming, DENG Qingchen, WU Yujuan, FU Penghuai, LIU Ziyi, WU Qianye, CHEN Kai, DING Wenjiang. Additive Manufacturing of Magnesium Alloys by Selective Laser Melting Technology: A Review. Acta Metall Sin, 2023, 59(1): 31-54.

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Abstract

Selective laser melting (SLM) additive manufacturing technology holds the broad prospect for the preparation of high-performance complex metal components owing to its high processing accuracy, short manufacturing cycle, and high material usage. Magnesium (Mg) alloys are the lightest metal structural material and provide the benefits of low density, substantial specific strength and specific stiffness, good damping and shock absorption performance, and good biodegradability. Thus, it is worthwhile to employ SLM to manufacture Mg alloys, which is predicted to widen the application scope of Mg alloys. In this study, a comprehensive review on SLM of Mg alloys focusing on the preparation of Mg alloy powders, SLM process parameters, metallurgical defects, microstructure and mechanical properties of the as-built state, post-processing, and special equipment developed for SLM of Mg alloys is given. Finally, the future development trends of the SLM of Mg alloys are explored.

Key words: selective laser melting (SLM) Mg alloy metallurgical defect post-processing microstructure mechanical property

Received: 09 April 2022

ZTFLH:

TG146.2

Fund: National Key Research and Development Program of China(2021YFB3701001);National Natural Science Foundation of China(51971130);National Natural Science Foundation of China(U21A2047);National Natural Science Foundation of China(51821001);National Natural Science Foundation of China(U2037601)

About author: DENG Qingchen, Tel: 18818221692, E-mail: dengqingchen@sjtu.edu.cn

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	Liming PENG
	Qingchen DENG
	Yujuan WU
	Penghuai FU
	Ziyi LIU
	Qianye WU
	Kai CHEN
	Wenjiang DING

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00166 OR https://www.ams.org.cn/EN/Y2023/V59/I1/31

Fig.1 Evaporative fumes (a) and macro cracks (b) during selective laser melting (SLM) of GWZ1031K alloy^[20]

Fig.2 Timeline displaying the historical background of research and development on SLM of Mg alloys (LPSO—long period stacking ordered, FSP—friction stir processing)

Table 1 Typical commercial grades of Mg powders

Fig.3 SEM characterization of 200-300 mesh GWZ1031K pre-alloyed powder (a-d)^[20]

Fig.4 V-S process map for SLM of GZ112K alloy (a), and defect features corresponding to the three processing zones: pores defects (b), forming zones (c), and lack of fusion defects (d)^[79] (V—scanning speed, S—hath spacing between adjacent laser scanning tracks)

Table 2 The process parameters for SLM of Mg alloys^{[18,26-28,30-32,34,42,43,46,51,52,63,64,66,69,75,79-81]}

Fig.5 Microstructures of the GZ112K alloy prepared by semi-continuous casting (a, b) and SLM (c, d)^[79]

Table 3 Room-temperature tensile properties of the as-built and post-processed Mg alloys fabricated by SLM under optimized process parameters^{[20,28,31-35,39,46,55,63,66,74,75,79-82,84]}

Fig.6 Comparisons of room temperature tensile properties of typical Mg alloys under as-cast, as-built, and as-extruded states^{[20,32,34,55,63,75,81,82,84]}(a) YS vs EL (b) UTS vs EL

Fig.7 The specific process of forming bubbles due to keyhole instability^[89] (d₁—keyhole depth, d₂—mini keyhole depth, P_i —keyhole pore)

Fig.8 Internal defect characteristics of the SLM-processed Mg-1Zn (a), Mg-2Zn (b), Mg-4Zn (c), Mg-6Zn (d), Mg-8Zn (e), Mg-10Zn (f), Mg-12Zn (g) and the measured crack content as well as relative density (h)^[46]

Fig.9 Crack distribution in longitudinal section of the as-built GZ151K cube^[83] (BD—building direction)

Fig.10 Microstructures of the solution treated GZ112K alloys at temperatures of 300^oC (a), 350^oC (b), 400^oC (c), 450^oC (d), 480^oC (e), 500^oC (f), and 520^oC (g) for 1 h, and the room-temperature tensile properties of the GZ112K alloys before and after heat treatment (h)^{[28,32-34,63,66,75,82,98-103]}

Fig.11 OM (a, b) and EBSD (c, d) images of the as-built (a, c) and FSPed (b, d) G10K alloy (FSP—friction stir processing)^[80]

Fig.12 Structure (a) and distribution of gas flow velocity (b) of the three types of blow-off screens, and mass fraction contours of Zn metal vapor under the optimized gas flow (c)^[97]

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