Metallurgy and Solidification Microstructure Control of Fusion-Based Additive Manufacturing Fabricated Metallic Alloys: A Review

doi:10.1007/s40195-023-01656-y

Abstract

Abstract:

The metal-based additive manufacturing (AM), also referred to as metal 3D printing, has drawn particular interest because it enables direct creation, aided by computationally-directed path design, of intricate components with site-specific compositions and geometrical requirements as well as low buy-to-fly ratios. During the last two decades, the objective of this revolutionary technology has been shifting from only “rapid prototyping” to advanced manufacturing of special high-end products or devices, which, in many aspects, outperform conventional manufacturing technologies. For fusion-based AM, significant progress has been achieved in understanding the processing window of macroscopic scales, non-equilibrium metallurgy of mesoscale scales, and grain evolution of microscopic scales. Although the versatile capacity of AM facilitates new avenues for discovering advanced materials and structures, their potential has still not been fully explored. Given the unique non-equilibrium solidification during the AM process, coarse columnar grains with strong textures are usually developed along the build direction, which downgrades the mechanical performance. To push the limits of this digital manufacturing, this review attempts to provide in-depth and comprehensive overviews of the recent progress in understanding the evolution and control of the as-built microstructure that has been made recently and the challenges encountered during the AM process.

Key words: Additive manufacturing, Temperature field, Microstructure control, Nanoparticles, Functionally graded materials

Qiang Li, Xing-Ran Li, Bai-Xin Dong, Xiao-Long Zhang, Shi-Li Shu, Feng Qiu, Lai-Chang Zhang, Zhi-Hui Zhang. Metallurgy and Solidification Microstructure Control of Fusion-Based Additive Manufacturing Fabricated Metallic Alloys: A Review[J]. Acta Metallurgica Sinica (English Letters), 2024, 37(1): 29-53.

Figures/Tables 9

Fig. 1 Schematical illustration of the fusion-based AM and the corresponding scientific aspects. Image sources from [72,73,74,75,76,77,78]

Fig. 2 Schematics illustration of two main fusion-based additive manufacturing systems: a PBF (SLM) [82], b DED (LMD) [83]

Fig. 3 Temperature distribution simulation of LPBF-produced IN 718 deposited on an IN 718 substrate using a laser power of 300 W and scanning speed of 15 mm/s [112]: a 1st layer; b 10th layer; c temperature distributions within a molten pool; d temperature variation simulation with time on the surface at varying locations while fixed x value; e comparison of the experimental data and numerical computation thermal cycle [16,112]

Fig. 4 Effects of high-intensity ultrasound on the microstructure morphology and size of a-d Ti-6Al-4V [123]; e, f 316L stainless steel [148]; the temperature field and nucleation behavior without g and with h high-intensity ultrasound [148]

Fig. 5 a Schematic illustration of the LPBF under a static magnetic field [52]; b simulated magnetic field for SLM [159]; c schematic illustration showing the Seebeck effect and coupling effects [52]; d Seebeck effect [52]; e and f X-Z and Y-Z planes [52]; EBSD analysis of LPBF-fabricated AlSi10Mg deposits under different SMF intensities: g 0 T and h 0.2 T [52]; WAAM fabricated Inconel 718 alloys without i and with j magnetic field, respectively [160]; k-n schematic illustration of the effects of magnetic field on the grain evolution [161]: k columnar growing without magnetic field; l thermal-electric-magnetic force acting on growing grains; m CET process and n the resultant microstructure under magnetic field

Fig. 6 Micrographs of laser melt deposition fabricated a Ti-6Al-4V and b Ti-8.5Cu alloy [181]; SLM-fabricated c AlScZr-1.5Mg alloy, d AlScZr-6.0Mg alloy, e AlScZr-6.0Mg-1.3Si alloy [182]; SLM-fabricated f pure Al, g Al-4.5Si and h Al-9Cu [183]; SLM-fabricated Al-Mg-Sc-Zr alloy using volumetric energy density and platform temperature of i 77.1 J/mm3, 35 °C; j 154.2 J/mm3, 35 °C; k 77.1 J/mm3, 200 °C; l 154.2 J/mm3, 200 °C [114]

Fig. 7 a Schematic illustration of the interplanar spacing mismatch, fd, and interatomic spacing misfit, fr, along the close-packed row pairs and between the close-packed plane pairs between TiN and γ-Fe and prior austenite grain structures of b H13 steel and c H13 steel with 0.5wt%TiN [231]; microstructures of WAAM fabricated d Ti-3Al-6C-4M-4Zr and e Ti-3Al-6C-4Mo-4Zr-0.5wt%La2O3 [155]; SLM-fabricated f Al10SiMg and g Al10SiMg-0.5wt%LaB6 [233]; schematic illustration of the solidification behavior of h AlSi10Mg and i AlSi10Mg-0.5wt%LaB6 during SLM [233]; j schematic illustration of the changes in the thermal fields in front of grain during AM, where NFZ represents nucleation free zone [117]

Fig. 8 a Effect of TiB2 nanoparticles on the laser reflectivity and absorption factor of the AlSi10Mg powder [222]; b schematic illustration of Marangoni convection and gravity within a molten pool [257]; c 3D reconstructed image showing the dispersion of LaB6 nanoparticles in a AlSi10Mg deposit [233]; in situ X-radiography showing more stable vapor depression with liquid breakup in d Al6061 and e no liquid breakup in Al6061 modified by TiC nanoparticles; f schematic illustration of nanoparticles preventing coalescence during spatter colliding; g nanoparticles arrangement between two colliding spatters; h capillary pressure is created by the nanoparticles; i nanoparticle improves stabilization of the vapor fluctuation; j spatter colliding formed agglomeration in Al6061 and (k) two spatters separated after colliding in modified Al6061 [77]

Fig. 9 a Typical structure of FGMs [78]; b OM morphology of LDED-fabricated spatially heterostructured AISI 420 stainless steel/C300 maraging steel and c, d their interface [78]; e the elytra prototype of the ironclad beetle with a typical interlocking structure [277,287]; f SS316l/in625 heterogeneous structure; g-j the interface of SS316l/in625 [277]; k Inconel 718/Ti64 bimetallic structure using a compositional bond layer [280]; l, m intermetallic manipulation of Inconel 718/Ti6Al4V through ultrasonic [281]

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