Fracture and fatigue in additively manufactured metals

Additive manufacturing is an emerging technique for manufacturing complex shapes rather than traditional manufacturing procedures due to the tool free manufacturing method. The complex components manufactured by this technique have a high surface roughness, which reduces fatigue strength, influences the wear of mating components, reduces the cooling efficiency of complex cooling channels, and so on. The surface roughness of complex cooling channels, for example, affects the formation of boundary layers, partial liquid flow, and heat transfer coefficients. As a result, the finishing processes are required for additively manufactured components to reduce the surface roughness. Chemical based finishing processes for additively manufactured parts have been developed by the researchers because it is a noncontact and automatic finishing process. However, a lack of understanding of the fundamental mechanisms governing these finishing processes may limit their practical uses in areas like aerospace, automobiles, and defense. In this review study, the mechanisms of various chemical and electrochemical based finishing processes are explained first, followed by the current state of the finishing processes of additively manufactured components. Surface integrity, for example, is controlled by experimental factors that are revealed first, followed by various researchers choosing acceptable input parameters to achieve the low surface roughness. In addition, this article provides future perspectives on finishing processes and a view into the process selection based on the component complexity and cost. 

State of the art on chemical and electrochemical based finishing processes for additive manufactured features

The influence of chemical etching on porous structure and mechanical properties of the Ti6AL4V Functionally Graded Porous Scaffolds fabricated by EBM

Post-Process Treatments for Additive-Manufactured Metallic Structures: A Comprehensive Review

Polishing of additive manufactured metallic components: retrospect on existing methods and future prospects

Metal additive manufacturing is increasingly utilised for the production of customised components Post-process operations are required to address the high surface roughness of as-built components which is detrimental for load-bearing applications Parts produced by metal additive manufacturing often have complex- surfaces and geometrical features rendering mechanical finishing processes impractical This study investigates the chemical polishing of laser powder bed fusion (LPBF) produced Ti6Al4V axial fatigue test specimens in HF-HNO3 solutions with different initial HF concentrations (1, 2, and 4 M) and a constant initial HNO3 concentration (317 M) Polishing efficacy was evaluated in terms of mass removal, surface roughness reduction, and resulting tension-tension fatigue strength The 4 M HF solution resulted in both the highest mass removal and surface roughness reduction; however, when evaluated relative to resource consumption, the processing efficiency decreases more drastically than that of the 1 and 2 M HF solutions Specimens polished in all three solutions had higher fatigue strengths and fewer surface crack initiation sites than the as-built condition Specimens polished in 2 M solutions exhibited better fatigue performance than specimens polished in 1 M solutions while statistical significance was lacking between the fatigue strengths of specimens polished in 2 M and 4 M solutions

The Effect of HF-HNO3 Chemical Polishing on the Surface Roughness and Fatigue Life of Laser Powder Bed Fusion Produced Ti6Al4V

To assess if a WC-9.2wt%Monel 400 alloy properties could be improved using LENS, one alloy was deposited onto a heated substrate and a second alloy was subjected to laser remelting of the final deposited layer. Microstructural characterization was performed using XRD, FESEM, EPMA, and Raman spectroscopy. Multiple microstructures were observed with eutectic, fishbone, and Fe/W-rich dendrites present in the fusion zone at the substrate-alloy interface, while needle-like, triangular and blocky carbides were found in the central regions, with acicular microstructures in the surface region. The alloy deposited onto the heated substrate had less eutectic and more fishbone structures in the fusion region. The laser remelted surface layer had a more homogenous acicular structure with minimal binder pooling compared to the other alloys. The spheroidal, cast WC/W2C powder particles were found to have core-rim structures after laser sintering. These microstructural variations resulted in a gradient hardness profile from the substrate-alloy interface to the alloy surface. The surface hardness of the laser remelted alloy was found to be significantly higher compared to the other alloys.

Microstructure characterization of WC-9.2wt%Monel 400 fabricated using laser engineered net shaping

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The Effect of HF-HNO3 Chemical Polishing on the Surface Roughness and Fatigue Life of Laser Powder Bed Fusion Produced Ti6Al4V

Microstructure characterization of WC-9.2wt%Monel 400 fabricated using laser engineered net shaping