Research Progress of Materials Design for Metal Laser Additive Manufacturing

doi:10.11900/0412.1961.2022.00026

Acta Metall Sin

2023, Vol. 59

Issue (1): 1-15 DOI: 10.11900/0412.1961.2022.00026

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Research Progress of Materials Design for Metal Laser Additive Manufacturing

SONG Bo, ZHANG Jinliang, ZHANG Yuanjie, HU Kai, FANG Ruxuan, JIANG Xin, ZHANG Xinru, WU Zusheng, SHI Yusheng(

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State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China

Cite this article:

SONG Bo, ZHANG Jinliang, ZHANG Yuanjie, HU Kai, FANG Ruxuan, JIANG Xin, ZHANG Xinru, WU Zusheng, SHI Yusheng. Research Progress of Materials Design for Metal Laser Additive Manufacturing. Acta Metall Sin, 2023, 59(1): 1-15.

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Abstract

Laser additive manufacturing is widely recognized to be an effective method to form complicated and custom metallic components. The existing research on metal additive manufacturing utilizes traditional alloy grades, which are designed based on the assumption that solidification occurs at equilibrium; thus, these materials are not well suited to the nonequilibrium metallurgical dynamics that are present in additive manufacturing techniques. Common issues, such as high crack susceptibility, low toughness, and low fatigue capability, as well as anisotropy, frequently occur during the fabrication of additively manufactured metallic parts. It is therefore necessary to conduct research on the design of new materials designed specifically for laser additive manufacturing in order to fully realize the potential advantages and value of the ultrafast solidification conditions. In this article, the technical bottlenecks, material design methods, and the development of new materials that are applicable to laser additively manufactured metal materials are reviewed; these materials include aluminum alloys, titanium alloys, iron-based alloys, and magnesium alloys. Finally, the potential future direction of research related to laser metal additive manufacturing is discussed.

Key words: laser additive manufacturing metal material design new material

Received: 19 January 2022

ZTFLH:

TG14

Fund: National Natural Science Foundation of China(51922044);China Postdoctoral Science Foundation Funded Project(2021M701293);China Postdoctoral Science Foundation Funded Project(2021M690061)

About author: SHI Yusheng, professor, Tel: (027)87558155, E-mail: shiyusheng@hust.edu.cn

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	Bo SONG
	Jinliang ZHANG
	Yuanjie ZHANG
	Kai HU
	Ruxuan FANG
	Xin JIANG
	Xinru ZHANG
	Zusheng WU
	Yusheng SHI

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00026 OR https://www.ams.org.cn/EN/Y2023/V59/I1/1

Fig.1 Schematics of laser additive manufacturing (LAM)^[10](a) selective laser melting (SLM) (b) laser cladding deposition (LCD)

Fig.2 Thermodynamic calculation of phase diagram (a), crack susceptibility factor (f_sis fraction solid) (b), and growth inhibition factor (Q_true) (c), inverse pole figures (IPFs) of Al alloys before (d) and after (e) Ti modification, grain size distributions and average grain sizes (f) of Ti-modified 2xxx Al alloys^[17]

Fig.3 Tensile properties of SLM-fabricated Ti alloys
(a) Ti-6Al-4V alloy^[27] (b) Ti-Cu alloys^[28]

Fig.4 Schematics of the microstructure evolution of (TiB + TiC)/Ti composites^[33]

Fig.5 Fe19Ni5Ti samples prepared by LCD and tensile tests ^[38]
(a) schematic of section temperature during forming (M_s—martensite start temperature)
(b) OM image of sample
(c) hierarchical structures of microstructure characteristics under different length scales
(d) tensile curves of two kinds of Fe19Ni5Ti (mass fraction, %) steel samples (Insets are the light microscope diagrams of two kinds of samples)

Fig.6 Microstructures and corrosion properties of SLM-fabricated stainless steel and Fe-based amorphous/stainless steel
(a, b) microstructures before (a) and after (b) polishing^[39] (Inset in Fig.6a is the energy spectrum of point 1, and the insets in Fig.6b are the surface energy spectrum and elements distribution) (c, d) IPFs before (c) and after (d) modification^[40] (e, f) comparisons of potentiostatic polarization test^[40] (I—corrosion current; T₁, T₂—start time of pitting corrosion; K₁, K₂—initial slope of the curve; SS—stainless steel)

Fig.7 Schematics of surface oxide formation^[76]
(a) dense Cr₂O₃ layer (b) Cr poor area
(c) Ni(Fe, Cr)₂O₄ layer (d) serious peeling of oxide layer

Fig.8 Solidification path (a) and crack sensitivity index (b) of NbMoTaX alloy^[88] (T—temperature)

Fig.9 Schematic of continuous cooling transformation (CCT) curve of amorphous alloy (a) and Fe-based amorphous structure (b)^[101] (R_c—critical cooling rate, R_cryst—crystallization cooling rate, R_SLM—SLM cooling rate, TPF—thermoplastic forming, t_p—maximum time to supercooled liquid region, t $p'$ —available time window of the heating step, T_L—liquidus temperature, T_g—glass transition temperature)

Fig.10 Mechanical properties of SLM-fabricated Fe based amorphous composites^[102] (BMG—bulk metallic glasses, K_J—fracture toughness)

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