Alloy design for laser powder bed fusion additive manufacturing: a critical review
Metal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM have persisted. These chall...
| Main Authors: | , , , , , , |
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| Format: | Article |
| Language: | English |
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IOP Publishing
2024-01-01
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| Series: | International Journal of Extreme Manufacturing |
| Subjects: | |
| Online Access: | https://doi.org/10.1088/2631-7990/ad1657 |
| _version_ | 1827390112840810496 |
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| author | Zhuangzhuang Liu Qihang Zhou Xiaokang Liang Xiebin Wang Guichuan Li Kim Vanmeensel Jianxin Xie |
| author_facet | Zhuangzhuang Liu Qihang Zhou Xiaokang Liang Xiebin Wang Guichuan Li Kim Vanmeensel Jianxin Xie |
| author_sort | Zhuangzhuang Liu |
| collection | DOAJ |
| description | Metal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM have persisted. These challenges arise because commercial alloys are primarily designed for conventional casting or forging processes, overlooking the fast cooling rates, steep temperature gradients and multiple thermal cycles of L-PBF. To address this, there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies. This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF. It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing alloys. The review begins by discussing the features of the L-PBF processes, focusing on rapid solidification and intrinsic heat treatment. Next, the printability of the four main existing alloys (Fe-, Ni-, Al- and Ti-based alloys) is critically assessed, with a comparison of their conventional weldability. It was found that the weldability criteria are not always applicable in estimating printability. Furthermore, the review presents recent advances in alloy development and associated strategies, categorizing them into crack mitigation-oriented, microstructure manipulation-oriented and machine learning-assisted approaches. Lastly, an outlook and suggestions are given to highlight the issues that need to be addressed in future work. |
| first_indexed | 2024-03-08T16:46:43Z |
| format | Article |
| id | doaj.art-0f0f5161afdb4582a00e6349efc18d91 |
| institution | Directory Open Access Journal |
| issn | 2631-7990 |
| language | English |
| last_indexed | 2024-03-08T16:46:43Z |
| publishDate | 2024-01-01 |
| publisher | IOP Publishing |
| record_format | Article |
| series | International Journal of Extreme Manufacturing |
| spelling | doaj.art-0f0f5161afdb4582a00e6349efc18d912024-01-05T09:35:26ZengIOP PublishingInternational Journal of Extreme Manufacturing2631-79902024-01-016202200210.1088/2631-7990/ad1657Alloy design for laser powder bed fusion additive manufacturing: a critical reviewZhuangzhuang Liu0https://orcid.org/0000-0002-9732-7338Qihang Zhou1Xiaokang Liang2Xiebin Wang3https://orcid.org/0000-0001-5132-6797Guichuan Li4Kim Vanmeensel5Jianxin Xie6Key Laboratory for Advanced Materials Processing (MOE), Institute for Advanced Materials and Technology, University of Science and Technology Beijing , Beijing 100083, People’s Republic of China; Beijing Advanced Innovation Center for Materials Genome Engineering, University of Science and Technology Beijing , Beijing 100083, People’s Republic of China; Beijing Laboratory of Metallic Materials and Processing for Modern Transportation, Institute for Advanced Materials and Technology, University of Science and Technology Beijing , Beijing 100083, People’s Republic of ChinaKey Laboratory for Advanced Materials Processing (MOE), Institute for Advanced Materials and Technology, University of Science and Technology Beijing , Beijing 100083, People’s Republic of ChinaCapital Aerospace Machinery Corporation Limited , Beijing 100076, People’s Republic of ChinaKey Laboratory for Liquid-Solid Structural Evolution and Processing of Materials (Ministry of Education), Shandong University , Jingshi Road 17923, Jinan 250061, People’s Republic of ChinaDepartment of Materials Engineering, KU Leuven , Leuven 3001, BelgiumDepartment of Materials Engineering, KU Leuven , Leuven 3001, BelgiumKey Laboratory for Advanced Materials Processing (MOE), Institute for Advanced Materials and Technology, University of Science and Technology Beijing , Beijing 100083, People’s Republic of China; Beijing Advanced Innovation Center for Materials Genome Engineering, University of Science and Technology Beijing , Beijing 100083, People’s Republic of China; Beijing Laboratory of Metallic Materials and Processing for Modern Transportation, Institute for Advanced Materials and Technology, University of Science and Technology Beijing , Beijing 100083, People’s Republic of ChinaMetal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM have persisted. These challenges arise because commercial alloys are primarily designed for conventional casting or forging processes, overlooking the fast cooling rates, steep temperature gradients and multiple thermal cycles of L-PBF. To address this, there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies. This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF. It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing alloys. The review begins by discussing the features of the L-PBF processes, focusing on rapid solidification and intrinsic heat treatment. Next, the printability of the four main existing alloys (Fe-, Ni-, Al- and Ti-based alloys) is critically assessed, with a comparison of their conventional weldability. It was found that the weldability criteria are not always applicable in estimating printability. Furthermore, the review presents recent advances in alloy development and associated strategies, categorizing them into crack mitigation-oriented, microstructure manipulation-oriented and machine learning-assisted approaches. Lastly, an outlook and suggestions are given to highlight the issues that need to be addressed in future work.https://doi.org/10.1088/2631-7990/ad1657laser powder bed fusionalloy designprintabilitycrack mitigation |
| spellingShingle | Zhuangzhuang Liu Qihang Zhou Xiaokang Liang Xiebin Wang Guichuan Li Kim Vanmeensel Jianxin Xie Alloy design for laser powder bed fusion additive manufacturing: a critical review International Journal of Extreme Manufacturing laser powder bed fusion alloy design printability crack mitigation |
| title | Alloy design for laser powder bed fusion additive manufacturing: a critical review |
| title_full | Alloy design for laser powder bed fusion additive manufacturing: a critical review |
| title_fullStr | Alloy design for laser powder bed fusion additive manufacturing: a critical review |
| title_full_unstemmed | Alloy design for laser powder bed fusion additive manufacturing: a critical review |
| title_short | Alloy design for laser powder bed fusion additive manufacturing: a critical review |
| title_sort | alloy design for laser powder bed fusion additive manufacturing a critical review |
| topic | laser powder bed fusion alloy design printability crack mitigation |
| url | https://doi.org/10.1088/2631-7990/ad1657 |
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