Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

King, W. E.; Anderson, A. T.; Ferencz, R. M.; Hodge, N. E.; Kamath, C.; Khairallah, S. A.; Rubencik, A. M.

doi:10.1063/1.4937809

Title: Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

Journal Article · Tue Dec 29 00:00:00 EST 2015 · Applied Physics Reviews

DOI:https://doi.org/10.1063/1.4937809· OSTI ID:1260471

King, W. E. ^[1]; Anderson, A. T. ^[1]; Ferencz, R. M. ^[1]; Hodge, N. E. ^[1]; Kamath, C. ^[1]; Khairallah, S. A. ^[1]; Rubencik, A. M. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this study, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1260471

Report Number(s):: LLNL-JRNL-676941

Journal Information:: Applied Physics Reviews, Vol. 2, Issue 4; ISSN 1931-9401 APRPG5

Publisher:: American Institute of PhysicsCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 609 works

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A Comprehensive Study of Steel Powders (316L, H13, P20 and 18Ni300) for Their Selective Laser Melting Additive Manufacturing Yan, Jujie; Zhou, Yinghao; Gu, Ruinan Metals, Vol. 9, Issue 1 https://doi.org/10.3390/met9010086	journal	January 2019
3D-printed components for quantum devices Saint, R.; Evans, W.; Zhou, Y. Scientific Reports, Vol. 8, Issue 1 https://doi.org/10.1038/s41598-018-26455-9	journal	May 2018
Thermoelectric magnetohydrodynamic control of melt pool dynamics and microstructure evolution in additive manufacturing Kao, A.; Gan, T.; Tonry, C. Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences, Vol. 378, Issue 2171 https://doi.org/10.1098/rsta.2019.0249	journal	April 2020
Crystallographic Features of Microstructure in Maraging Steel Fabricated by Selective Laser Melting Takata, Naoki; Nishida, Ryoya; Suzuki, Asuka https://doi.org/10.20944/preprints201805.0373.v1	preprint	May 2018
Dual-use distinguishability: How 3D-printing shapes the security dilemma for nuclear programs Volpe, Tristan A. Emerging Technologies and International Stability https://doi.org/10.4324/9781003179917-9	book	September 2021
On the primary spacing and microsegregation of cellular dendrites in laser deposited Ni-Nb alloys Ghosh, Supriyo; Ma, Li; Ofori-Opoku, Nana arXiv https://doi.org/10.48550/arxiv.1705.06669	text	January 2017
Uncertainty Analysis of Microsegregation during Laser Powder Bed Fusion Ghosh, Supriyo; Mahmoudi, Mohamad; Johnson, Luke arXiv https://doi.org/10.48550/arxiv.1902.06785	text	January 2019
Finite Element Analysis of Interaction of Laser Beam with Material in Laser Metal Powder Bed Fusion Process Fu, Guang; Zhang, David; He, Allen Materials, Vol. 11, Issue 5 https://doi.org/10.3390/ma11050765	journal	May 2018
Effect of Scanning and Support Strategies on Relative Density of SLM-ed H13 Steel in Relation to Specimen Size Kurzynowski, Tomasz; Stopyra, Wojciech; Gruber, Konrad Materials, Vol. 12, Issue 2 https://doi.org/10.3390/ma12020239	journal	January 2019
Study on the Numerical Simulation of the SLM Molten Pool Dynamic Behavior of a Nickel-Based Superalloy on the Workpiece Scale Cao, Liu; Yuan, Xuefeng Materials, Vol. 12, Issue 14 https://doi.org/10.3390/ma12142272	journal	July 2019

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