Unlike conventional materials removal methods, additive manufacturing (AM) is based on a novel materials incremental manufacturing philosophy. Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser. The current development focus of AM is to produce complex shaped functional metallic components, including metals, alloys and metal matrix composites (MMCs), to meet demanding requirements from aerospace, defence, automotive and biomedical industries. Laser sintering (LS), laser melting (LM) and laser metal deposition (LMD) are presently regarded as the three most versatile AM processes. Laser based AM processes generally have a complex non-equilibrium physical and chemical metallurgical nature, which is material and process dependent. The influence of material characteristics and processing conditions on metallurgical mechanisms and resultant microstructural and mechanical properties of AM proc...

Laser additive manufacturing of metallic components: materials, processes and mechanisms

Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component is built by selectively melting and fusing powders within and between layers. The SLM technique is also commonly known as direct selective laser sintering, LaserCusing, and direct metal laser sintering, and this technique has been proven to produce near net-shape parts up to 99.9% relative density. This enables the process to build near full density functional parts and has viable economic benefits. Recent developments of fibre optics and high-power laser have also enabled SLM to process different metallic materials, such as copper, aluminium, and tungsten. Similarly, this has also opened up research opportunities in SLM of ceramic and composite materials. The review presents the SLM process and some of the common physical phenomena associated with this AM technology. It then focuses on the following a...

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Review of selective laser melting : materials and applications

Consolidation phenomena in laser and powder-bed based layered manufacturing

Finite element simulation of the temperature and stress fields in single layers built without-support in selective laser melting

Balling phenomena in direct laser sintering of stainless steel powder: Metallurgical mechanisms and control methods

This paper presents a detailed investigation into the influence of the rare earth (RE) oxide (La2O3) addition upon the densification and the resultant microstructural characteristics of the submicron WC–Co particulate reinforced Cu matrix composites prepared by direct laser sintering. It is found that the relative density of the laser sintered sample with 1 wt.% La2O3 addition increased by 11.5% as compared with the sample without RE addition. The addition of RE element favored the microstructural refinement and improved the particulate dispersion homogeneity and the particulate/matrix interfacial coherence. The metallurgical functions of the RE element in improving the sinterability were also addressed. It shows that due to the unique properties of RE element such as high surface activity and large atomic radius, the addition of trace RE element can decrease the surface tension of the melt, resist the grain growth coarsening and increase the heterogeneous nucleation rate during laser sintering.

Effect of rare earth oxide addition on microstructures of ultra-fine WC-Co particulate reinforced Cu matrix composites prepared by direct laser sintering

Metallurgical mechanisms in direct laser sintering of Cu-CuSn-CuP mixed powder

As for 2.5D layer-to-layer angle interlock braided composites, a new finite element model of 2.5D braided composites is established, which truly simulate the profile and tending towards of tows in fabric. The material properties of tows are defined to variate with the undulation of tows in this model. The finite element software ANSYS is adopted to study the mechanical properties of 2.5D braided composites and presented its stress nephogram, and the influence of the arranged density of the warp and weft tows on the elastic moduli of this material is analyzed in detail. Then, samples are made by resin transfer molding (RTM) technique and tensile tests are performed to determine the mechanical properties. Finally, the present models are found to correlate reasonably well with the experimental, predicted and measured results available in the literature.

Finite element analysis of the tensile properties of 2.5D braided composites

Homogenizing the particulate dispersion in the matrix is an important consideration in obtaining high-quality particulate reinforced metal matrix composites (MMCs) using direct metal laser sintering (DMLS). In this paper, the effects of processing parameters in terms of laser power, scan speed, and powder layer thickness on the particulate dispersion in the DMLS-processed submicron WC–Co p /Cu 1 MMCs were investigated. It shows that for a given scan speed larger than 0.04 m/s, a proper increase in the laser power between ∼650 W and ∼750 W leads to a uniform dispersion of smooth and fine WC particulates, due to a sufficient liquid formation and an improved wettability. Whereas, an excessive increase in the laser power results in a severe particulate aggregation, because of the balling effect. There exists a critical scan speed of 0.04 m/s, above which the particulates can be well engulfed by the advancing dendritic front, thereby homogenizing the particulate dispersion in the matrix. A proper decrease in the powder layer thickness to 0.20 mm can alleviate the particulate aggregation, due to the elevated Marangoni convection and liquid capillary forces.

Influence of processing parameters on particulate dispersion in direct laser sintered WC–Cop/Cu MMCs

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Papers

Effect of rare earth oxide addition on microstructures of ultra-fine WC-Co particulate reinforced Cu matrix composites prepared by direct laser sintering

Metallurgical mechanisms in direct laser sintering of Cu-CuSn-CuP mixed powder

Finite element analysis of the tensile properties of 2.5D braided composites

Influence of processing parameters on particulate dispersion in direct laser sintered WC–Cop/Cu MMCs