Recent advances in Ti-6Al-4V additively manufactured by selective laser melting for biomedical implants: Prospect development

Investigation of layer-by-layer laser remelting to improve surface quality, microstructure, and mechanical properties of laser powder bed fused AlSi10Mg alloy

Growing maturity of SLM has enabled the use of rapid manufacturing technology on hard-to-machine Ti alloys. In this review, selective laser melted titanium alloys are reviewed based on the ever-growing database recently. This study aims to systematically collect relevant and up-to-date information from an exhaustive literature on selective laser melted Ti alloys including the detailed elaboration of recent advances on fabrication, post-processing, microstructure characteristics, mechanical and biocompatibility performances, simulation as well as their correlation of Ti alloys for engineering applications manufactured by SLM. By summarizing the state-of-the-art progress of SLM Ti alloys, five future perspectives on challenges and prospects perspectives for SLM Ti alloys are proposed accordingly. This review advances the associated limitations and overcoming attempts, providing a better understanding and future perceptions on the interdependency between different aspects in this field. 

Additive manufacturing of titanium alloys via selective laser melting: Fabrication, microstructure, post-processing, performance and prospect

The aim of selective laser melting (SLM) technology is to obtain high quality workpieces through optimization of processing parameters. However, the defects and microstructures are simultaneously changed with the change of process parameters, so their effects are hard to discuss separately. To meet this challenge, 24 combinations of laser power and scanning speed were designed to fabricate the SLM manufactured Ti6Al4V alloy, and the volumetric energy density (VED) of them ranges from 30 J/mm3 to 100 J/mm3. It is found that with the increase of VED the prior β boundary tended to be straighter and wider, while the morphology of α lamella did no change distinctively. The porosity varies from nearly 0% to 4% in this process zone, which has significant effects on the tensile properties. For samples with high porosity (0.25%–4%), the influence of defects covered the influence of microstructure, leading to stochastic ultimate tensile strength and stably low elongation. For samples with low porosity (0.01%–0.25%) and extra-low porosity (

Effects of defects and microstructures on tensile properties of selective laser melted Ti6Al4V alloys fabricated in the optimal process zone

A356 alloys processed mostly with the low pressure die casting method are always known to contain casting pores and inhomogeneous microstructure. In this study, the effects of microstructure coarsening and casting pores on the tensile and high-cycle fatigue properties of A356-T6 alloy are comprehensively investigated. The deformation behavior and fracture mechanisms are systematically analyzed by combining tensile tests and crystal plasticity finite element method (CP-FEM) simulations with distinctively initial microstructure features (fine microstructure, coarse microstructure, and coarse microstructure with pores). The results show that microstructure coarsening is presented in the notably grown α-Al dendrites, which leads to the connection and thickening of eutectic regions accompanied by the aggregative distribution of eutectic Si particles. With the coarsening microstructure, microcrack is easier to initiate in those thick eutectic regions, due to the higher stress concentration caused by the aggregated eutectic silicon. Particularly, the dominant crack propagation path changes from the trans -dendrite for fine microstructure to along eutectic regions with coarse microstructure. In addition, it confirms that the casting pores have larger detrimental effects on the tensile and fatigue properties than the microstructure coarsening in the aspects of crack initiation. Stress concentration is prone to be induced at the local edge of pore at the initial loading stage, resulting in the micro plastic deformation and lower fatigue properties. With the rapid strain accumulation in later stage, the microcracks can initiate prematurely at the local edge of pore, and thus lead to obvious decrease in tensile elongation. Moreover, a modified fatigue model considering the effects of casting pores and the microstructure difference is proposed to describe the fatigue performance of A356-T6 alloy. • Microstructure coarsening significantly deteriorates the elongation of cast A356-T6 alloy. • Aggregation of eutectic silicon particles leads to the premature initiation of microcracks. • The casting pores have larger detrimental effects on the tensile and fatigue properties than the microstructure coarsening. • A new modified fatigue model coupling the effects of casting pores and the microstructure difference is proposed. 

Effects of microstructure coarsening and casting pores on the tensile and fatigue properties of cast A356-T6 aluminum alloy: A comparative investigation

Effects of electropulsing on the microstructure and microhardness of a selective laser melted Ti6Al4V alloy

Selective laser melting (SLM) is one of the most promising additive manufacturing (AM) technologies in recent years. However, some sub-millimeter defects often appear accidently in SLM specimens, resulting in deterioration of mechanical properties. Therefore, the effects of these defects on the mechanical properties of the SLM materials are significantly important. In this study, the effect of a single spherical defect on the tensile properties was investigated by embedding a spherical pore inside the SLM Ti6Al4V specimens. Different combinations of pore diameters (Ф100 μm, Ф300 μm, Ф500 μm, Ф1000 μm) and locations (center, sub-surface, near-surface) were designed to mimic the sub-millimeter printing defects. The results demonstrated that these embedded pores had negligible influence on the elastic modulus and tensile strength but had a noticeable influence on the tensile elongation. With the increase of pore size, the elongation to failure of the specimens tended to be stochastic, stably high and stably low in sequence, which could be related to different fracture modes. The tensile specimens fractured at the embedded pore when the embedded pore size was increased to a critical diameter (approximately Ф1000 μm). Concurrently, the location of the embedded pore started to have an obvious influence on ductility, namely, the elongation to failure decreased as the embedded pore became closer to free surface.

Effects of embedded spherical pore on the tensile properties of a selective laser melted Ti6Al4V alloy

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Papers

Effects of electropulsing on the microstructure and microhardness of a selective laser melted Ti6Al4V alloy

Effects of defects and microstructures on tensile properties of selective laser melted Ti6Al4V alloys fabricated in the optimal process zone

Effects of embedded spherical pore on the tensile properties of a selective laser melted Ti6Al4V alloy