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Material Design and Defect Control for Metal Additive Manufacturing

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 August 2023) | Viewed by 22285

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Special Issue Editor

Prof. Dr. Huajie Yang

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Guest Editor

Shi-changxu Innovation Center for Advanced Materials, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
Interests: additive manufacturing; mechanical property; defect and damage healing; electroplasticity; severe plastic deformation; fatigue and fracture

Special Issue Information

Dear Colleagues,

Metal Additive manufacturing (AM) technology plays a significant role in various fields such as aircraft manufacturing, automotive manufacturing and medical applications for its design freedom, material saving and in near net shape fabrication. Currently, the metal AM research mainly focuses on a limited number of alloys due to their availability in powder form. These alloys were designed for casting, forging, rolling, but not for AM. As such, it is essential that new AM-specific alloys need to be designed and evaluated. These alloys should have low cracking susceptibility, less likelihood for residual stress development, and less prone to porosity formation. In addition, the flexibility that AM offers in creating tailored microstructure, i.e. multi-materials, heterogeneous or harmonic microstructures for extending the existing applications. Thus, the development of AM technologies is significant to create novel structures tailored for the performance and function required by the application. Furthermore, the AM part quality is greatly influenced by the applied AM processes, deposition methodologies, and post-processing technologies. The studies about microstructure/defects characterization, microstructure/defects–mechanical property relationship and the effect of post-processing treatments are needed to create desired AM parts with enhanced mechanical performances. Therefore, this Special Issue shall focus on the latest works related to the AM technologies and their applications using advanced materials. Topics can include but are not limited to:

Novel materials for additive manufacturing;
Design methods for multifunctional and heterogeneous microstructures;
Post-processing technologies for AM parts (HIP, HT, shot peening, electropulsing and more);
Advanced characterizations for AM materials (SEM, TEM, synchrotron radiation diffraction, neutron scattering, and more);
Process parameter–microstructure/defects–mechanical property relationships

We are pleased to invite you to submit original, high-quality scientific articles, short communications, and state-of-the-art reviews for this Special Issue. Both theoretical and experimental contributions are warmly welcomed.

Prof. Dr. Huajie Yang
Guest Editor

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Keywords

additive manufacturing
mechanical properties
microstructural characterization
alloys development
heterogeneous microstructure
post-processing technology
fatigue and fracture

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Published Papers (6 papers)

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Research

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22 pages, 24049 KiB

Open AccessArticle

Comparison of the Structure, Mechanical Properties and Effect of Heat Treatment on Alloy Inconel 718 Produced by Conventional Technology and by Additive Layer Manufacturing

by Martin Švec, Pavel Solfronk, Iva Nováková, Jiří Sobotka and Jaromír Moravec

Materials 2023, 16(15), 5382; https://doi.org/10.3390/ma16155382 - 31 Jul 2023

Cited by 4 | Viewed by 1614

Abstract

The nickel-iron-based alloy Inconel 718 is a progressive material with very good mechanical properties at elevated and lower temperatures. It is used both as wrought and cast alloys as well as material for additive manufacturing technologies. This is the reason why it has received so much attention, as supported by numerous publications. However, these are almost exclusively focused on a specific type of production and processing, and thus only report differences in the mechanical properties between samples prepared by different technologies. Therefore, the major aim of this research was to show how the structure and mechanical properties differ between samples produced by conventional production (wrought alloy) and additively manufactured SLM (Selective Laser Melting). It is shown that by applying appropriate heat treatment, similar strength properties at room and elevated temperatures can be achieved for SLM samples as for wrought samples. In addition, the mechanical properties are also tested up to a temperature of 900 °C, in contrast to the results published so far. Furthermore, it is proven that the microstructures of the wrought (here rolled) and SLM alloys differ significantly both in terms of grain shape and the size and distribution of precipitates. Full article

(This article belongs to the Special Issue Material Design and Defect Control for Metal Additive Manufacturing)

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14 pages, 12624 KiB

Open AccessFeature PaperArticle

Significance of Melt Pool Structure on the Hydrogen Embrittlement Behavior of a Selective Laser-Melted 316L Austenitic Stainless Steel

by Jie Liu, Huajie Yang, Lingxiao Meng, Di Liu, Tianqi Xu, Daokui Xu, Xiaohong Shao, Chenwei Shao, Shujun Li, Peng Zhang and Zhefeng Zhang

Materials 2023, 16(4), 1741; https://doi.org/10.3390/ma16041741 - 20 Feb 2023

Cited by 7 | Viewed by 2627

Abstract

The hydrogen embrittlement (HE) behavior of a selective laser-melted (SLM) 316L austenitic stainless steel has been investigated by hydrogen charging experiments and slow strain rate tensile tests (SSRTs) at room temperature. The results revealed that compared to the samples without H, the ultimate tensile strength (UTS) and elongation (EL) of specimens were decreased from 572 MPa to 552 MPa and from 60% to 36%, respectively, after 4 h of electrochemical hydrogenation with a current density of 100 mA/cm². The negative effects of hydrogen charging were more pronounced on the samples’ ductility than on their strength. A quasi in situ EBSD observation proved that there was little phase transformation in the samples but an increased density of low angle grain boundaries, after 4 h H charging. After strain was applied, the surface of the H-sample displayed many hydrogen-induced cracks along the melt pool boundaries (MPBs) showing that these MPBs were the preferred areas for the gathering and transferring of hydrogen. Full article

(This article belongs to the Special Issue Material Design and Defect Control for Metal Additive Manufacturing)

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15 pages, 5144 KiB

Open AccessArticle

Enhanced Strength and Hardness of AS41 Magnesium Alloy Fabricated by Selective Laser Melting

by Ruirui Yang, Keyu Chen, Shifeng Wen, Shijie Zhu, Haotian Qin, Xiaochao Wu, Yan Zhou, Yusi Che, Yusheng Shi and Jilin He

Materials 2022, 15(17), 5863; https://doi.org/10.3390/ma15175863 - 25 Aug 2022

Cited by 3 | Viewed by 1900

Abstract

AS41 magnesium alloy possesses outstanding performance features such as light weight, high strength to toughness ratio and excellent heat resistance due to the addition of Si element, while traditional casting methods are prone to inducing large grain size and coarse Mg₂Si phase. In this study, we first reported utilizing the selective laser melting (SLM) technique, fabricating AS41 samples and exploring the effect of laser energy densities on the metallurgical quality by characterizing and investigating the microstructure and mechanical properties. Results showed that the optimal laser energy density range was 60 to 100 J/mm³. Average grain size of only 2.9 μm was obtained with weak texture strength of 1.65 in {0001} orientation. Meanwhile, many dispersed secondary β-Mg₁₇Al₁₂ and Mg₂Si phases were distributed inside the α-Mg matrix. It was confirmed that the SLM process introduced more grain recrystallization, inducing giant high-angle grain boundaries (HAGBs) and hindering the movement of dislocations, therefore forming dislocation strengthening while achieving grain refinement strengthening. Finally, three times the ultimate tensile strength of 313.7 MPa and higher microhardness of 96.4 HV than those of the as-cast state were obtained, verifying that the combined effect of grain refinement, solid solution strengthening and precipitation strengthening was responsible for the increased strength. This work provides new insight and a new approach to preparing AS41 magnesium alloy. Full article

(This article belongs to the Special Issue Material Design and Defect Control for Metal Additive Manufacturing)

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13 pages, 5891 KiB

Open AccessArticle

Microstructure and Corrosion Resistance of Underwater Laser Cladded Duplex Stainless Steel Coating after Underwater Laser Remelting Processing

by Congwei Li, Jialei Zhu, Zhihai Cai, Le Mei, Xiangdong Jiao, Xian Du and Kai Wang

Materials 2021, 14(17), 4965; https://doi.org/10.3390/ma14174965 - 31 Aug 2021

Cited by 17 | Viewed by 2460

Abstract

Combined with the technologies of underwater local dry laser cladding (ULDLC) and underwater local dry laser remelting (ULDLR), a duplex stainless steel (DSS) coating has been made in an underwater environment. The phase composition, microstructure, chemical components and electrochemical corrosion resistance was studied. The results show that after underwater laser remelting, the phase composition of DSS coating remains unchanged and the phase transformation from Widmanstätten austenite + intragranular austenite + (211) ferrite to (110) ferrite occurred. The ULDLR process can improve the corrosion resistance of the underwater local dry laser cladded coating. The corrosion resistance of remelted coating at 3 kW is the best, the corrosion resistance of remelted coating at 1kW and 5kW is similar and the corrosion resistance of (110) ferrite phase is better than grain boundary austenite phase. The ULDLC + ULDLR process can meet the requirements of efficient underwater maintenance, forming quality control and corrosion resistance. It can also be used to repair the surface of S32101 duplex stainless steel in underwater environment. Full article

(This article belongs to the Special Issue Material Design and Defect Control for Metal Additive Manufacturing)

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14 pages, 4523 KiB

Open AccessEditor’s ChoiceArticle

Application of Additively Manufactured Pentamode Metamaterials in Sodium/Inconel 718 Heat Pipes

by Longfei Hu, Ketian Shi, Xiaoguang Luo, Jijun Yu, Bangcheng Ai and Chao Liu

Materials 2021, 14(11), 3016; https://doi.org/10.3390/ma14113016 - 2 Jun 2021

Cited by 4 | Viewed by 5743

Abstract

In this study, pentamode metamaterials were proposed for thermal stress accommodation of alkali metal heat pipes. Sodium/Inconel 718 heat pipes with and without pentamode metamaterial reinforcement were designed and fabricated. Then, these heat pipes were characterized by startup tests and thermal response simulations. It was found that pentamode metamaterial reinforcement did not affect the startup properties of sodium/Inconel 718 heat pipes. At 650–950 °C heating, there was a successful startup of heat pipes with and without pentamode metamaterial reinforcement, displaying uniform temperature distributions. A further simulation indicated that pentamode metamaterials could accommodate thermal stresses in sodium/Inconel 718 heat pipes. With pentamode metamaterial reinforcement, stresses in the heat pipes decreased from 12.9–62.1 to 10.2–52.4 MPa. As a result, sodium/Inconel 718 heat pipes could be used more confidently. This work was instructive for the engineering application of alkali metal heat pipes. Full article

(This article belongs to the Special Issue Material Design and Defect Control for Metal Additive Manufacturing)

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Review

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14 pages, 6985 KiB

Open AccessReview

Research Status and Prospect of Additive Manufactured Nickel-Titanium Shape Memory Alloys

by Shifeng Wen, Jie Gan, Fei Li, Yan Zhou, Chunze Yan and Yusheng Shi

Materials 2021, 14(16), 4496; https://doi.org/10.3390/ma14164496 - 11 Aug 2021

Cited by 38 | Viewed by 6020

Abstract

Nickel-titanium alloys have been widely used in biomedical, aerospace and other fields due to their shape memory effect, superelastic effect, as well as biocompatible and elasto-thermal properties. Additive manufacturing (AM) technology can form complex and fine structures, which greatly expands the application range of Ni-Ti alloy. In this study, the development trend of additive manufactured Ni-Ti alloy was analyzed. Subsequently, the most widely used selective laser melting (SLM) process for forming Ni-Ti alloy was summarized. Especially, the relationship between Ni-Ti alloy materials, SLM processing parameters, microstructure and properties of Ni-Ti alloy formed by SLM was revealed. The research status of Ni-Ti alloy formed by wire arc additive manufacturing (WAAM), electron beam melting (EBM), directional energy dedication (DED), selective laser sintering (SLS) and other AM processes was briefly described, and its mechanical properties were emphatically expounded. Finally, several suggestions concerning Ni-Ti alloy material preparation, structure design, forming technology and forming equipment in the future were put forward in order to accelerate the engineering application process of additive manufactured Ni-Ti alloy. This study provides a useful reference for scientific research and engineering application of additive manufactured Ni-Ti alloys. Full article

(This article belongs to the Special Issue Material Design and Defect Control for Metal Additive Manufacturing)

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