Progress in additive manufacturing on new materials: A review

doi:10.1016/j.jmst.2018.09.002

Abstract

Abstract:

Recent efforts and advances in additive manufacturing (AM) on different types of new materials are presented and reviewed. Special attention is paid to the material design of cladding layers, the choice of feedstock materials, the metallurgical behavior and synthesis principle during the AM process, and the resulted microstructures and properties, as well as the relationship between these factors. Thereafter, the trend of development in the future is forecasted, including: Effects of the particles size and size distribution of powders; Approaches for producing fine microstructures; Opportunities for creating new materials by AM; Wide applications in reconditioning of damaged components; Challenges for deep understanding and applications of the AMed new materials. The idea of “Develop Materials” or “Create Materials” by AM is highlighted, but a series of scientific, technological and engineering problems remain to be solved in future.

Key words: Additive manufacturing, Feedstock material, Laser and electron beam melting, Microstructure, Property

Neng Li, Shuai Huang, Guodong Zhang, Renyao Qin, Wei Liu, Huaping Xiong, Gongqi Shi, Jon Blackburn. Progress in additive manufacturing on new materials: A review[J]. J. Mater. Sci. Technol., 2019, 35(2): 242-269.

Figures/Tables 43

Fig. 1. Additive manufacturing of 7075 Al alloy via selective laser. (a) Al7075 powder functionalized with nanoparticles. (b) Equiaxed grain growth. (c) Functionalizing the powder feedstock with nanoparticles produces fine equiaxed grain growth and eliminates hot cracking [13].

Fig. 2. SEM images of microstructure. (a) Cast AZ31 alloy. (b) Phase microstructure analysis of AZ31 alloy processed with SLM [14].

Fig. 3. IPF maps of the α-phase and calculated prior-β phase (X _ dir. ‖ ND) captured from the “cross-section” YZ plane (a), (b), respectively, and section of a [-110]-oriented stereographic projection with relevant planes/directions identified (c)[21].

Fig. 4. Microstructure of electron beam deposited Ti-8Al-1Er (a) and Ti-6Al-4 V (b), normal to build direction [27].

Fig. 5. 3D-optical micrograph composite section view for 17-4PH stainless steel fabricated by SLM. The build direction is shown by arrow at lower right [3].

Fig. 6. (a) 3D-optical microscopy image composite section view for alloy 625 component fabricated by EBM. The build direction is noted by the arrow (lower right). (b) TEM bright-field image showing Ni3Nb bct precipitate plates coincident with NiCr fcc {111} planes noted. The vertical reference plane view corresponds to (a) [3,37].

Fig. 7. Optical micrograph of the lengthwise section of the first half of a CMSX-4 sample with the starting edge on the left side of the image [48].

Table 1 Tensile YS and UTS in the (L-T) plane of the Inconel 718 EBF3 block in the AD and the HT conditions [41].

Orientation	Property	AD (measured) (MPa)	HT (measured) (MPa)	Cast (literature) (MPa)	Wrought (literature) (MPa)
L	YS	655	986	488	1182
L	UTS	978	1114	786	1369
T	YS	699	998	-	1208
T	UTS	936	1162	-	1374
45 deg	YS	703	995	-	-
45 deg	UTS	993	1171	-	-

Fig. 8. Microstructure of the as-deposited Ti-40Al-2Cr (a, b) and Ti-47Al-2.5V-1Cr (c, d) alloy [63,64].

Fig. 9. Microstructure of the SLM-processed Ti-45Al-2Cr-5Nb alloy [66].

Fig. 10. Microstructure of the vertical cross-section of at θ = 0° (a), 45° (b), and 90° (c), at high magnification [73].

Fig. 11. BSE images of the as-deposited alloy (a), and the alloy annealed at 1500 °C for 24 h in flowing argon (b). Processing parameters: laser power = 432 W, powder feed rate = 18.1 g/min, scan speed = 400 mm/min [82].

Fig. 12. Schematics of LMD with dual powder feeding method [83].

Fig. 13. BSE images of the as-deposited Nb-17Si-23Ti alloys fabricated by LMD with the laser power of 1 kW (a) and 2 kW (b), and BSE images of longitudinal sections (c) and transversal sections (d) for the as-deposited Nb-17Si-23Ti alloys with DS microstructure. Inserts are enlarged images, and arrows indicate the build direction [83].

Fig. 14. Schematic reaction process that takes place in Al12Si20Ti/SiC coating. (a) An SiC particle in a molten Al-Ti matrix. (b) Reaction between SiC particle and molten Al. (c) Reaction between molten Ti with Al4C3 and Si. (d) Al and TiC ring formation [90].

Fig. 15. EBSD maps of AA6061/TiC in situ composite containing TiC. (a) 0; (b) 2.5%; (c) 5% [91].

Fig. 16. Evolution mechanism of SLM-processed B4C/Ti composite parts at variable laser power: (a) 125 W, 800 mm/s, (b) 200 W, 800 mm/s [93].

Fig. 17. Bright-field TEM micrograph of micro-morphology of TiC in eutectic austenite (a) and HREM image of TiC-γ-Ni interface (b) [98].

Fig. 18. Gradient distribution of TiC particles and Microhardness variation with the coating depth [98].

Fig. 19. Microstructure of Inconel 690/TiC samples. (a) Equiaxed grains found in 8.7 vol.% TiC. (b) Groups of columnar dendrites in 15.3 vol.% TiC layer. (c) Dendritic TiC phase (43 vol.% TiC) [99].

Fig. 20. Transmission electron microscopic images of TiC particles in primary dendrites of γ-Ni (a) and dislocation (b) [101].

Fig. 21. Microstructure of as-fabricated WCp/NiBSi MMC (a) and higher magnification (b) [106].

Fig. 22. Diagram illustration for the action mechanism of Ti on the microstructure of VN alloy/Co-based composite coatings [112].

Fig. 23. Laser cladding high Co-Ni steel coating on 18Cr2Ni4WA steel: (a) cross-section morphology of coating and substrate; (b) and (c) SEM micrograph of coating and substrate, 1- martensite, 2- retained austenite, 3- M3C cementite, 4- M2C carbides; (d) locating pins in airplane repaired using laser cladding technology [113].

Fig. 24. Typical SEM view of (a) SS/HA and (b) 316 L SS microstructure [114].

Fig. 25. SEM images of the microstructure of (a) 316 L alloy and composites reinforced with (b) 3 wt% PCS. (c) 7 wt% PCS[115].

Fig. 26. Scheme of the printing process for carbon fiber reinforced PLA composites [135,136].

Fig. 27. Chain-mail structure consisting of joint rings hanging on supporting walls, showing possibility to fabricate flexible scaffolds [138].

Fig. 28. (a) FESEM image of the dry mixed alumina/zirconia powder. (b) Phase diagram of the alumina and zirconia system [142].

Fig. 29. SEM micrographs showing the dispersion of CaF2 spheres in the inter-plate regions of the laser clad Al2O3-30%CaF2 ceramic matrix composite coating [145].

Fig. 30. BEIs of different gradient layers. (a) 40% SiC; (b) 60% SiC; (c) 70% SiC [146].

Fig. 31. Microstructure of SiC + Si laser clad coating. (a) Cross-section of a strip obtained by using SiC + Si powder mixture as raw material. (b) Detail of the SiC/Si composite coating (the circle is a SiC grain) [153].

Fig. 32. Optical micrograph of the compositionally Ti-Co system graded interface [157].

Fig. 33. Macro-surface of the LMD Ti/TiAl SGM component (a). Microstructure of the as-deposited Ti-43Al-1.8V-0.8Cr (b). TEM BF of Ti-43Al-1.8V-0.8Cr (c). Ti-30Al-1.4V-0.5Cr (d). Ti-17Al-V-1.8Zr-Mo (e), and Ti-6.5Al-V-2Zr-Mo (f) [159].

Fig. 34. Gradient composite coating of cross section (a). Morphology of WC particles in wear-resisting layer (b), and interlayer II (c) [160].

Fig. 35. Cross-section gradient microstructure of Ti/SiC bulk FGM sample [146].

Fig. 36. Schematic description, and fabricated part of rotator cuff scaffold [165].

Fig. 37. (a) Microstructures of the parts manufactured at laser scan speeds of 550 mm s-1. (b) The fracture surface of the samples. (c) An example of precise acetabular cup produced by SLM [171].

Fig. 38. EBSD phase maps (a, c, e) and IPF maps (b, d, f) on longitudinal cross-section of different height of as-EBM-built rod. (a, b) top part. (c, d) center part and (e, f) bottom part [178].

Table 2 Room temperature compressive properties of the equiatomic AlCoCrFeNi HEA produced by SEBM and casting [187].

	ε_f (%)	σ_0.2 (MPa)	σ_max (MPa)
Casting	5.6 ± 1.9	1308.3 ± 77.3	1425.0 ± 127.5
SSEBM (0°)	26.4 ± 6.7	1015.0 ± 52.5	1668.3 ± 71.5
SSEBM (90°)	14.5 ± 5.3	944.0 ± 55.4	1447.0 ± 135.8

Fig. 39. IPF maps and phase maps of the cast and the SEBM specimens of the equiatomic AlCoCrFeNi HEA obtained at the cross-section perpendicular to the build direction at the top and bottom sections [188].

Fig. 40. EBSD phase map of (a) Al-0.4. (b) Al-0.7, and (c) Al-1.0 arc-melted samples showing fcc (red) and bcc (green) phases. (d) Grain size distributions of the fcc and bcc phases of the arc-melted samples [189].

Fig. 41. Tensile strength and pitting potential of SEBM specimens under different conditions. (a) Tensile engineering stress-engineering strain curves; (b) Potentiodynamic polarization curves [193].

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