Metal additive manufacturing in aerospace: A review

Powder Bed Fusion (PBF) techniques constitute a family of Additive Manufacturing (AM) processes, which are characterised by high design flexibility and no tooling requirement. This makes PBF techniques attractive to many modern manufacturing sectors (e.g. aerospace, defence, energy and automotive) where some materials, such as Nickel-based superalloys, cannot be easily processed using conventional subtractive techniques. Nickel-based superalloys are crucial materials in modern engineering and underpin the performance of many advanced mechanical systems. Their physical properties (high mechanical integrity at high temperature) make them difficult to process via traditional techniques. Consequently, manufacture of nickel-based superalloys using PBF platforms has attracted significant attention. To permit a wider application, a deep understanding of their mechanical behaviour and relation to process needs to be achieved. The motivation for this paper is to provide a comprehensive review of the mechanical properties of PBF nickel-based superalloys and how process parameters affect these, and to aid practitioners in identifying the shortcomings and the opportunities in this field. Therefore, this paper aims to review research contributions regarding the microstructure and mechanical properties of nickel-based superalloys, manufactured using the two principle PBF techniques: Laser Powder Bed Fusion (LPBF) and Electron Beam Melting (EBM). The ‘target’ microstructures are introduced alongside the characteristics of those produced by PBF process, followed by an overview of the most used building processes, as well as build quality inspection techniques. A comprehensive evaluation of the mechanical properties, including tensile strength, hardness, shear strength, fatigue resistance, creep resistance and fracture toughness of PBF nickel-based superalloys are analysed. This work concludes with summary tables for data published on these properties serving as a quick reference to scholars. Characteristic process factors influencing functional performance are also discussed and compared throughout for the purpose of identifying research opportunities and directing the research community toward the end goal of achieving part integrity that extends beyond static components only.

Powder Bed Fusion of nickel-based superalloys: A review

Wire arc additive manufacturing (WAAM) has been considered as a promising technology for the production of large metallic structures with high deposition rates and low cost. Stainless steels are widely applied due to good mechanical properties and excellent corrosion resistance. This paper reviews the current status of stainless steel WAAM, covering the microstructure, mechanical properties, and defects related to different stainless steels and process parameters. Residual stress and distortion of the WAAM manufactured components are discussed. Specific WAAM techniques, material compositions, process parameters, shielding gas composition, post heat treatments, microstructure, and defects can significantly influence the mechanical properties of WAAM stainless steels. To achieve high quality WAAM stainless steel parts, there is still a strong need to further study the underlying physical metallurgy mechanisms of the WAAM process and post heat treatments to optimize the WAAM and heat treatment parameters and thus control the microstructure. WAAM samples often show considerable anisotropy both in microstructure and mechanical properties. The new in-situ rolling + WAAM process is very effective in reducing the anisotropy, which also can reduce the residual stress and distortion. For future industrial applications, fatigue properties, and corrosion behaviors of WAAMed stainless steels need to be deeply studied in the future. Additionally, further efforts should be made to improve the WAAM process to achieve faster deposition rates and better-quality control.

https://www.mdpi.com/2076-3417/10/5/1563/pdf

Wire arc additive manufacturing of stainless steels: A review

The current state-of-the-art metal additive manufacturing (AM) process still cannot meet the high industry requirements in terms of surface roughness. In addition, there are limited ISO/ASTM standa...

A review on the state-of-the-art of surface finishing processes and related ISO/ASTM standards for metal additive manufactured components

Tremendous growth has been witnessed in the field of additive manufacturing (AM) technology over the last few decades. It offers a plethora of applications and is already being utilized in almost every sphere of life. Owing to inherent differences between each AM technique, newer fields of research consistently emerge and demand attention. Also, the innovative applications of AM open up newer challenges and thus avenues for focused attention. One such avenue is AM materials. Raw material plays an important role in determining the properties of fabricated part. The type and form of raw material largely depend on the type of AM fabricators. There is a restriction on material compatibility with most of the established AM techniques. This review aims to provide an overview of various aspects of AM materials highlighting the progress made especially over the past two decades. 

/pdf/a-review-of-various-materials-for-additive-manufacturing-3gz3885y.pdf

A review of various materials for additive manufacturing: recent trends and processing issues

WC-Co hardmetals are widely used in wear-resistant parts, cutting tools, molds, and mining parts, owing to the combination of high hardness and high toughness. WC-Co hardmetal parts are usually produced by casting and powder metallurgy, which cannot manufacture parts with complex geometries and often require post-processing such as machining. Additive manufacturing (AM) technologies are able to fabricate parts with high geometric complexity and reduce post-processing. Therefore, additive manufacturing of WC-Co hardmetals has been widely studied in recent years. In this article, the current status of additive manufacturing of WC-Co hardmetals is reviewed. The advantages and disadvantages of different AM processes used for producing WC-Co parts, including selective laser melting (SLM), selective electron beam melting (SEBM), binder jet additive manufacturing (BJAM), 3D gel-printing (3DGP), and fused filament fabrication (FFF) are discussed. The studies on microstructures, defects, and mechanical properties of WC-Co parts manufactured by different AM processes are reviewed. Finally, the remaining challenges in additive manufacturing of WC-Co hardmetals are pointed out and suggestions on future research are discussed.

/pdf/additive-manufacturing-of-wc-co-hardmetals-a-review-20z4ocs4xw.pdf

Additive manufacturing of WC-Co hardmetals: a review

The Inconel 625 (IN625) superalloy has a high strength, excellent fatigue, and creep resistance under high-temperature and high-pressure conditions, and is one of the critical materials used for manufacturing high-temperature bearing parts of aeroengines. However, the poor workability of IN625 alloy prevents IN625 superalloy to be used in wider applications, especially in applications requiring high geometrical complexity. Laser powder bed fusion (LPBF) is a powerful additive manufacturing process which can produce metal parts with high geometrical complexity and freedom. This paper reviews the studies that have been done on LPBF of IN625 focusing on the microstructure, mechanical properties, the development of residual stresses, and the mechanism of defect formation. Mechanical properties such as microhardness, tensile properties, and fatigue properties reported by different researchers are systematically summarized and analyzed. Finally, the remaining issues and suggestions on future research on LPBF of IN625 alloy parts are put forward.

https://www.mdpi.com/2076-3417/10/1/81/pdf

A Review on Laser Powder Bed Fusion of Inconel 625 Nickel-Based Alloy

Aluminum (Al) and copper (Cu) have been widely used in many industrial fields thanks to their good plasticity, high thermal conductivity and excellent electrical conductivity. An effective joining of dissimilar Al and Cu materials can make full use of the special characteristics of these two metals. Friction stir spot welding (FSSW), as an efficient solid-state welding method suitable for joining of dissimilar metal materials, has great prospects in future industrial applications. In this paper, the FSSW studies on Al-Cu dissimilar materials are reviewed. The research progress and current status of Al-Cu FSSW are reviewed with respect to tool features, macroscopic characteristics of welded joints, microstructures, defects in welds and mechanical properties of joints. In addition, some suggestions on further study are put forward in order to promote the development and progress of Al-Cu FSSW studies in several respects: material flow, thermal history, addition of intermediate layer, auxiliary methods and functionalization of Al-Cu FSSW joint.

https://www.mdpi.com/1996-1944/13/1/156/pdf

Friction Stir Spot Welding of Aluminum and Copper: A Review.

The invention provides an additive manufacturing method of a stainless steel-magnesium interlocking bi-metal part in a complex shape. The method comprises the steps that a stainless steel complex thin-shell cavity with tree-branch-shaped protrusions on the surface of an inner cavity is manufactured through a selective laser melting molding process; a molten magnesium alloy containing aluminum is injected into the stainless steel complex thin-shell cavity in a high-temperature state through a reserved hole; a stainless steel-magnesium complex part in the high-temperature state is subjected to vibration treatment, so that the stainless steel cavity is fully filled with the molten magnesium alloy; vibration treatment is continuously applied in the part cooling process, and defects like shrinkage cavities are prevented; and finally, the reserved hole is completely plugged through an argon arc welding process. The method can manufacture the stainless steel-magnesium interlocking bi-metal part in the complex shape, reliable mechanical interlocking between the stainless steel cavity and a magnesium alloy matrix is achieved, and good metallurgical bonding is also achieved under help of thealuminum element.

Additive manufacturing method of stainless steel-magnesium interlocking bi-metal part in complex shape

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Papers

Additive manufacturing of WC-Co hardmetals: a review

A Review on Laser Powder Bed Fusion of Inconel 625 Nickel-Based Alloy

Friction Stir Spot Welding of Aluminum and Copper: A Review.

Additive manufacturing method of stainless steel-magnesium interlocking bi-metal part in complex shape