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Printability of alloys for additive manufacturing.

ABSTRACT: Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal distortion. A theoretical kinetic model is used to examine predisposition of different alloys to AM induced compositional changes. A well-tested numerical heat transfer and fluid flow model is used to compare susceptibilities of various alloys to lack of fusion defects. These results are tested and validated with independent experimental data. The findings presented in this paper are aimed at achieving distortion free, compositionally sound and well bonded metallic parts.

SUBMITTER: Mukherjee T

PROVIDER: S-EPMC4726422 | biostudies-literature | 2016 Jan

REPOSITORIES: biostudies-literature

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Printability of alloys for additive manufacturing.

Mukherjee T T Zuback J S JS De A A DebRoy T T

Scientific reports 20160122

Although additive manufacturing (AM), or three dimensional (3D) printing, provides significant advantages over existing manufacturing techniques, metallic parts produced by AM are susceptible to distortion, lack of fusion defects and compositional changes. Here we show that the printability, or the ability of an alloy to avoid these defects, can be examined by developing and testing appropriate theories. A theoretical scaling analysis is used to test vulnerability of various alloys to thermal di ...[more]

PMID: 26796864

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Project description:Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives such as reduced part numbers, greater functionality, and lightweight, among others. Polymers, metals, and ceramics are the few materials that can be used in AM technology, but metallic materials (Magnesium and Aluminum) are attracting more attention from the research and industrial point of view. Understanding the role processing parameters of laser-based additive manufacturing is critical to maximize the usage of material in forming the product geometry. LPBF (Laser powder-based fusion) method is regarded as a potent and effective additive manufacturing technique for creating intricate 3D forms/parts with high levels of precision and reproducibility together with acceptable metallurgical characteristics. While dealing with LBPF, some degree of porosity is acceptable because it is unavoidable; hot ripping and cracking must be avoided, though. The necessary manufacturing of pre-alloyed powder and ductility remains to be the primary concern while dealing with a laser-based additive manufacturing approach. The presence of the Al-Si eutectic phase in AlSi10Mg and AlSi12 alloy attributing to excellent castability and low shrinkage, attaining the most attention in the laser-based approach. Related studies with these alloys along with precipitation hardening and heat treatment processing were discussed. The Pure Mg, Mg-Al alloy, Mg-RE alloy, and Mg-Zn alloy along with the mechanical characteristics, electrochemical durability, and biocompatibility of Mg-based material have been elaborated in the work-study. The review article also summarizes the processing parameters of the additive manufacturing powder-based approach relating to different Mg-based alloys. For future aspects, the optimization of processing parameters, composition of the alloy, and quality of powder material used will significantly improve the ductility of additively manufactured Mg alloy by the LPBF approach. Other than that, the recycling of Mg-alloy powder hasn't been investigated yet. Meanwhile, the post-processing approach, including a homogeneous coating on the porous scaffolds, will mark the suitability in terms of future advancements in Mg and Al-based alloys.

Dataset Information

Printability of alloys for additive manufacturing.

Publications

Printability of alloys for additive manufacturing.

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