A review of selective laser melting of aluminum alloys: Processing, microstructure, property and developing trends

Processing parameters in laser powder bed fusion metal additive manufacturing

Mechanistic models for additive manufacturing of metallic components

Additive Manufacturing (AM) has revolutionized the manufacturing industry in several directions. Laser powder bed fusion (LPBF), a powder bed fusion AM process, has been dramatically accepted in various industries due to its versatility with several materials, including alloys. This comprehensive review article primarily explains the basic principle of the LPBF process, scientific and technological progress of several inter-related parameters, feedstock materials, produced properties/defects, and insights of numerical modelling to virtually understand the process behavior. Specific attention has been given to selective laser-meted (LPBFed) properties, driven through the microstructure formations and, thereby, concerning defects. The scope of the post-processing techniques to refine microstructure has also been discussed in this review paper. It has been identified that the defects are vital in LPBF process and are primarily governed by the process parameters. Therefore, a wisely chosen, optimized set of parameters can play a crucial role in minimizing defects considerably. Finally, the numerical modeling discussed in this review paper will help the researchers understand the LPBF process. 

Laser Powder Bed Fusion: A State-of-the-Art Review of the Technology, Materials, Properties & Defects, and Numerical Modelling

Reliable computational models of metal additive manufacturing will assist in optimising part quality, and are likely to play a role in component qualification. A key component of these models will be a detailed simulation of flow and heat transfer in and around the melt pool formed as the powder bed is melted. This paper reviews the burgeoning literature concerning melt pool simulation. The physical theory underlying the current benchmark models is first presented and the main approximations and assumptions discussed. The individual capabilities of the leading simulation groups around the world are listed in detail. Publications by less prominent research groups are also summarised. Finally, the overall status of melt pool simulation and the implications for model development are discussed.

Simulation of Melt Pool Behaviour during Additive Manufacturing: Underlying Physics and Progress

Numerical simulation of multi-component evaporation during selective electron beam melting of TiAl

In additive manufacturing using laser or electron beam melting technologies, evaporation losses and changes in chemical composition are known issues when processing alloys with volatile elements. In this paper, a recently described numerical model based on a two-dimensional free surface lattice Boltzmann method is further developed to incorporate the effects of multi-component evaporation. The model takes into account the local melt pool composition during heating and fusion of metal powder. For validation, the titanium alloy Ti–6Al–4V is melted by selective electron beam melting and analysed using mass loss measurements and high-resolution microprobe imaging. Numerically determined evaporation losses and spatial distributions of aluminium compare well with experimental data. Predictions of the melt pool formation in bulk samples provide insight into the competition between the loss of volatile alloying elements from the irradiated surface and their advective redistribution within the molten region.

https://iopscience.iop.org/article/10.1088/1361-651X/aa5289/pdf

A multi-component evaporation model for beam melting processes

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Numerical simulation of multi-component evaporation during selective electron beam melting of TiAl

A multi-component evaporation model for beam melting processes