Ni loss and phase structure formed during pulse laser powder bed fusion of Nitinol

The La-Mg-Ni-based A2B7-type La0.8Mg0.2Ni3.3Co0.2Si x (x=0–0.2) electrode alloys were prepared by casting and annealing. The influences of the additional silicon and the annealing treatment on the structure and electrochemical performances of the alloys were investigated systemically. Both of the analyses of XRD and SEM reveal that the as-cast and annealed alloys are of a multiphase structure, involving two main phases (La, Mg)2Ni7 and LaNi5 as well as one minor phase LaNi3. The addition of Si and annealing treatment bring on an evident change in the phase abundances and cell parameters of (La, Mg)2Ni7 and LaNi5 phase for the alloy without altering its phase structure. The phase abundances decrease from 74.3% (x=0) to 57.8% (x=0.2) for the (La, Mg)2Ni7 phase, and those of LaNi5 phase increase from 20.2% (x=0) to 37.3% (x=0.2). As for the electrochemical measurements, adding Si and performing annealing treatment have engendered obvious impacts. The cycle stability of the alloys is improved dramatically, being enhanced from 80.3% to 93.7% for the as-annealed (950 °C) alloys with Si content increasing from 0 to 0.2. However, the discharge capacity is reduced by adding Si, from 399.4 to 345.3 mA·h/g as the Si content increases from 0 to 0.2. Furthermore, such addition makes the electrochemical kinetic properties of the alloy electrodes first increase and then decrease. Also, it is found that the overall electrochemical properties of the alloys first augment and then fall with the annealing temperature rising.

Effect of process parameters on the formation of single track in pulsed laser powder bed fusion

Depending on the application, establishing a strategy for selecting the type of powder bed fusion technology—from electron beam (EB-PBF) or laser powder bed fusion (L-PBF)—is important. In this study, we focused on the β-type Ti–15Mo–5Zr–3Al alloy (expected for hard-tissue implant applications) as a model material, and we examined the variations in the microstructure, crystallographic texture, and resultant mechanical properties of specimens fabricated by L-PBF and EB-PBF. Because the melting mode transforms from the conduction mode to the keyhole mode with an increase in the energy density in L-PBF, the relative density of the L-PBF-built specimen decreases at higher energy densities, unlike that of the EB-PBF-built specimen. Although both EB-PBF and L-PBF can obtain cubic crystallographic textures via bidirectional scanning with a 90° rotation in each layer, the formation mechanisms of the textures were found to be different. The <100> texture in the build direction is mainly derived from the vertically grown columnar cells in EB-PBF, whereas it is derived from the vertically and horizontally grown columnar cells in L-PBF. Consequently, different textures were developed via bidirectional scanning without rotation in each layer: the <110> and <100> aligned textures along the build direction in L-PBF and EB-PBF, respectively. The L-PBF-built specimen exhibited considerably better ductility, but slightly lower strength than the EB-PBF-built specimen, under the conditions of the same crystallographic texture and relative density. We attributed this to the variation in the microstructures of the specimens; the formation of the α-phase was completely absent in the L-PBF-built specimen. The results demonstrate the importance of properly selecting the two technologies according to the material and its application.

In the Laser Powder Bed Fusion (L-PBF) process, 3D components with complex geometries are fabricated in a layer-by-layer fashion by using a controlled laser beam to selectively melt particular regions of the metal powder bed. However, due to the stochastic nature of the L-PBF process, the top surface roughness of each solidified layer tends to be different even when the optimal processing conditions for the different positions on the build plate are employed. As a result, the mechanical properties of the built components frequently vary from one component to the next. Accordingly, this study proposes an Intelligent Additive Manufacturing Architecture (IAMA) for controlling the surface roughness of each build layer through an appropriate adjustment of the laser re-melting parameters. The IAMA architecture comprises five modules, namely In-Situ Metrology (ISM), Ex-Situ Metrology (ESM), Automatic Virtual Metrology (AVM), Additive Manufacturing Simulation (AMS) and Intelligent Compensator (IC). The feasibility of the proposed architecture is demonstrated by comparing the top surface roughness of cubic and mechanical strengths of tensile test samples built using the proposed method with those built using a traditional L-PBF approach without surface roughness control. It is found that the samples fabricated using the IAMA approach have an average top surface roughness of <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$1.6~\mu \text{m}$ </tex-math></inline-formula> and a standard deviation is <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$0.7~\mu \text{m}$ </tex-math></inline-formula> . By contrast, the samples produced using the traditional L-PBF approach have an average surface roughness of <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$13.45~\mu \text{m}$ </tex-math></inline-formula> and a standard deviation of <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$2.5~\mu \text{m}$ </tex-math></inline-formula> . In addition, the specimens produced with the assistance of IAMA architecture have an average tensile strength of 1013 MPa with a standard deviation of 69.5 MPa, while those printed without surface roughness control have an average tensile strength of 903 MPa with a standard deviation of 101.4 MPa Note to Practitioners—As L-PBF produce part in a layer-by-layer manner, therefore, the roughness on the top surface of previous layer have a strong influence on the printing quality of current layer. The variations of surface roughness will lead to the fluctuation of mechanical properties of the fabricated components. Additionally, to the best of author’s knowledge, current commercial L-PBF machines can not actively control the surface roughness of samples during the process. The proposed IAMA in this work can predict and control the roughness on the top surface of each layer during L-PBF process. Therefore, the constructed architecture has strong potential for integrating into the commercial L-PBF machine for controlling the surface roughness on the top of the parts during the manufacturing process. As a result, the quality of the fabricated components is expected to be in consistent. Accordingly, L-PBF machine equipped with IAMA will have a strong potential in applying for mass production of the components in aerospace and automobile industries.

Microstructure and physical properties of a Ni/Fe-based superalloy processed by Selective Laser Melting

In laser powder bed fusion (LPBF) processes, the powder size characteristics, like particle shape, particle size (PS), particle size distribution (PSD), and the resulting powder bed density (PBD), are key influencing factors of the built material properties. To better understand the correlations between the powder size characteristics and the powder properties influencing the LPBF process, apparent density (AD), flowability, and PBD were measured corresponding to two commercial metal powders with different PS and PSD. The powder samples were taken from different locations on the build platform to also investigate the variations of these powder characteristics resulting from the spreading process by the stiff recoater blade. It was shown that the PS and PSD had a significant effect on the AD and the PBD. Powders with a wide PSD and with particle sizes in the range of the effective powder layer thickness, led to a higher PBD than powder with a high proportion of finer particles. No significant differences in PS and PSD were observed as powder was pushed across a build plate by the recoater blade.

Mechanical properties and cytocompatibility of dense and porous Zn produced by laser powder bed fusion for biodegradable implant applications

Effect of shielding conditions on bead profile and melting behaviour in laser powder bed fusion additive manufacturing

Laser powder bed fusion (LPBF) is an additive manufacturing process which can produce complex 3D parts from digital models. The performance of parts fabricated by LPBF is largely dependent on the characteristics of the powder feedstock, in particular, the particle size distribution. The coarsening of powder particles may limit the potential for reusing powder in further builds, as consistency in powder quality is crucial for ensuring consistent parts performance when using reused powder, especially in aerospace applications. However, there is a lack of systematic understanding regarding the causes and nature of powder coarsening in LPBF. In this work, the characteristics of powder samples from different locations in the build chamber during LPBF were studied to understand the particle size evolution and determine the origin of coarsening, which has not been previously reported. Meanwhile, powder coarsening was found to have a detrimental effect on the relative density and surface quality of as-built parts, highlighting the importance of exploring the mechanisms of powder coarsening and finding ways to control it in LPBF. The relationship between powder in key locations in the build chamber and its effect on powder coarsening has been established. Layer thickness is identified as a critical factor in causing powder coarsening due to the fine powder size characteristic in the powder bed. Spatter, in its various forms, plays a direct or indirect role in powder coarsening. Sintered powders resulting from spatter and the laser scanning borders of as-built parts were observed to contribute to the powder coarsening. Therefore, three main mechanisms (layer thickness, spatter, sintered powder) associated with the powder coarsening are therefore proposed. This work provides insight and potential solutions to control powder coarsening and maintain consistent parts performance.

Additive manufacturing (AM) is an emerging process that has been extremely improved in terms of technology and application in recent years. In this technology review, new industrial improvements in laser powder bed fusion (LPBF) of metals are discussed. LPBF has the lowest build rate among all AM processes that produce metals such as electron beam powder bed fusion, direct energy deposition, binder jetting and sheet lamination. The findings of the current research show that the most innovations and future directions of LPBF printers are toward increasing the speed of the process by using interchangeable feedstock chamber, closed-loop control powder handling, automated powder sieving, multi-layer concurrent printing, 2-axis coating and multi powder hoppers. To increase the speed of the process, the new improvements for transferring time and using fast lasers are presented. Another innovation in the building of LPBF printers is enhancing part quality by improving lasers with the shorter beam diameter, multi-lasers, uniform inert gas flow, accurate positioning systems, using high vacuum systems and using sensors and automation.

One of the state-of-the-art technologies for metal fabrication is laser powder bed fusion, which includes the following printing techniques: selective laser melting, selective laser sintering, direct metal laser sintering, and electron beam melting. This work examines defect formation in laser powder bed fusion, predominately focusing on selective laser melting. It also explores recent research findings on defect formation and classification and analyzes various internal defects, such as porosity, lack of fusion, balling, and solidification cracking. The influence of process parameters on defect formation and the effect of defects on mechanical properties are analyzed. This review also discusses defect inspection technologies (melt pool, scan path, and slice monitoring), defect mitigation strategies (online detection, process parameters, and numerical simulation), and their applications in additive manufacturing, such as laser powder bed fusion. This review would aid manufacturers in determining the root cause of defect formation and developing inspection technologies and mitigation strategies.

Laser powder bed fusion (LPBF) is a widely used Additive Manufacturing (AM) process involving a high-powered laser to fuse metal powder and build up successive layers to create complex structures. Process parameter selection significantly impacts the dimensional characteristics of the melt pool morphology, including its depth and width, which is vital to the final print quality. Accurately predicting the melt-pool depth is critical for ensuring the quality of the final product. Various methods for different materials have been investigated, for example, thermal image analysis, analytical methods like scaling law, machine learning, and so on. However, most of the promising results are only studies for one material, and it is not necessarily fully applied to another material. In this paper, our study involves utilizing machine learning models to make predictions of melt-pool depth in the LPBF process and compare their performance to an analytical approach based on scaling law with Nickel alloys IN625 and IN718. We trained three different machine learning models which are Gaussian Process Regression (GPR), Support Vector Machines (SVM), and Neural Networks (NN), and evaluated their performance using R-squared error and Root Mean Squared Error (RMSE) against the performance of the analytical scaling law. Our results show that the machine learning models outperform the scaling law approach significantly. This study demonstrates the potential of machine learning for improving the accuracy of melt-pool depth prediction in LPBF and provides insights into the strengths and limitations of different machine learning models for this task.

Powder spreading is a crucial step in the powder bed fusion process, which controls the quality of powder bed and consequently affects the quality of printed parts. To date, however, powder spreadability has received very little attention and substantial fundamental work is still needed, largely because of the lack of experimental studies. Therefore, the focus of the present study addresses the influences of powder morphology, spreading velocity and layer thickness on the powder bed topography uniformity. The experiments were conducted with a laser powder bed fusion printer and the powder layers were spread systematically and comprehensively assessed. In summary, it was found that particle sphericity and surface texture dictates the degree of impact that the spreader velocity and the layer thickness exert on the quality of powder bed topography in spread layers. The spreader velocity has substantial influence on powder bed uniformity, such that better uniformity is achieved with low spreading velocities, ≤ 80 mm/s. Powders with a wide particle distribution and containing large number of fine particles (< 25 µm) enabled formation of uniform and dense powder beds, however such powders were found to be more affected by segregation. In addition to these observed effects, for the first time, the major process related challenges to powder spreadability and powder bed quality are reported in this study.

Two of the processes of metallic additive manufacturing that are currently in a strong industrial development are the Selective Laser Melting (SLM), within the additive process category assigned as "Powder Bed Fusion (PBF)" and the Laser Metal Deposition (LMD), as part of "Direct Energy Deposition (DED)" processes. Thus, in this paper the combination of both additive manufacturing techniques (SLM + LMD) is studied, so that, a hybrid method that combines the advantages of both processes is applied. To analyze the applicability of this methodology, the case of a turbine component manufactured by SLM, to which structures have been added later by means of LMD, is presented. On the other hand, the critical areas of the part in which there is a concurrence of problems that force a change in the process have been analyzed. In addition, a technique to prepare the areas where material is going to be supplied by LMD has been applied to reduce the possible thermal damage that is generated during this process. Keywords: SLM, LMD, additive manufacturing, Inconel 718®, aeronautical turbines.

Mapping of residual stresses in as-built Inconel 718 fabricated by laser powder bed fusion: A neutron diffraction study of build orientation influence on residual stresses