The metallurgy and processing science of metal additive manufacturing

Sames, William J.; List, III, Frederick Alyious; Pannala, Sreekanth; Dehoff, Ryan R.; Babu, Sudarsanam Suresh

doi:10.1080/09506608.2015.1116649

Title: The metallurgy and processing science of metal additive manufacturing

Journal Article · Mon Mar 07 00:00:00 EST 2016 · International Materials Reviews

DOI:https://doi.org/10.1080/09506608.2015.1116649· OSTI ID:1267051

Sames, William J. ^[1]; List, III, Frederick Alyious ^[2]; Pannala, Sreekanth ^[2]; Dehoff, Ryan R. ^[2]; Babu, Sudarsanam Suresh ^[3]

Texas A & M Univ., College Station, TX (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Univ. of Tennessee, Knoxville, TN (United States)

Here, additive Manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire, or sheets in a process that proceeds layer-by-layer.Many techniques (using many different names) have been developed to accomplish this via melting or solid - state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid- state precipitation, mechanical properties, and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Few alloys have been developed for commercial production, but recent development efforts are presented as a path for the ongoing development of new materials for AM processes.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility (MDF)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1267051

Journal Information:: International Materials Reviews, Vol. 61, Issue 5; ISSN 0950-6608

Publisher:: Taylor & FrancisCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 1354 works

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The Hardness of Additively Manufactured Alloys Zuback, J. S.; DebRoy, T. Materials, Vol. 11, Issue 11 https://doi.org/10.3390/ma11112070	journal	October 2018
Dynamic simulation of powder packing structure for powder bed additive manufacturing Lee, Y. S.; Nandwana, P.; Zhang, W. The International Journal of Advanced Manufacturing Technology, Vol. 96, Issue 1-4 https://doi.org/10.1007/s00170-018-1697-3	journal	February 2018
Machine Learning-Enabled Competitive Grain Growth Behavior Study in Directed Energy Deposition Fabricated Ti6Al4V Li, Jinghao; Sage, Manuel; Guan, Xiaoyi JOM, Vol. 72, Issue 1 https://doi.org/10.1007/s11837-019-03917-7	journal	November 2019
The Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al6061 and AlSi10Mg Alloys Maamoun, Ahmed; Xue, Yi; Elbestawi, Mohamed Materials, Vol. 12, Issue 1 https://doi.org/10.3390/ma12010012	journal	December 2018
Influence of Postbuild Microstructure on the Electrochemical Behavior of Additively Manufactured 17-4 PH Stainless Steel Stoudt, M. R.; Ricker, R. E.; Lass, E. A. JOM, Vol. 69, Issue 3 https://doi.org/10.1007/s11837-016-2237-y	journal	January 2017
The third Sandia fracture challenge: predictions of ductile fracture in additively manufactured metal Kramer, Sharlotte L. B.; Jones, Amanda; Mostafa, Ahmed International Journal of Fracture, Vol. 218, Issue 1-2 https://doi.org/10.1007/s10704-019-00361-1	journal	July 2019
Contribution of cellulosic fibre filter on atmosphere moisture content in laser powder bed fusion additive manufacturing Das, A.; Muñiz-Lerma, J. A.; Espiritu, E. R. L. Scientific Reports, Vol. 9, Issue 1 https://doi.org/10.1038/s41598-019-50238-5	journal	September 2019
Effects of powders and process parameters on density and hardness of A357 aluminum alloy fabricated by selective laser melting Tonelli, Lavinia; Liverani, Erica; Valli, Giuseppe The International Journal of Advanced Manufacturing Technology, Vol. 106, Issue 1-2 https://doi.org/10.1007/s00170-019-04641-x	journal	November 2019
Thermocapillary instabilities in a horizontal liquid layer under partial basal slip Kowal, Katarzyna N.; Davis, Stephen H.; Voorhees, Peter W. Journal of Fluid Mechanics, Vol. 855 https://doi.org/10.1017/jfm.2018.684	journal	September 2018
Comparison of virgin and reused 15-5 PH stainless steel powders for laser powder bed fusion process Zhang, Jing; Hu, Bin; Zhang, Yi Progress in Additive Manufacturing, Vol. 3, Issue 1-2 https://doi.org/10.1007/s40964-018-0038-2	journal	January 2018
Single-Track Melt-Pool Measurements and Microstructures in Inconel 625 Ghosh, Supriyo; Ma, Li; Levine, Lyle E. JOM, Vol. 70, Issue 6 https://doi.org/10.1007/s11837-018-2771-x	journal	February 2018
Development of Bulk Metallic Glass Matrix Composites (BMGMC) by Additive Manufacturing: Modelling and Simulation – A Review: Part B Rafique, Muhammad Musaddique Ali; Niezgoda, Stephen; Brandt, Milan Advanced Materials Research, Vol. 1154 https://doi.org/10.4028/www.scientific.net/amr.1154.40	journal	June 2019
Laser‐Based Additive Manufacturing Technologies for Aerospace Applications Tepylo, Nick; Huang, Xiao; Patnaik, Prakash C. Advanced Engineering Materials, Vol. 21, Issue 11 https://doi.org/10.1002/adem.201900617	journal	September 2019
Programmable Mechanical Properties of Two‐Photon Polymerized Materials: From Nanowires to Bulk Bauer, Jens; Guell Izard, Anna; Zhang, Yunfei Advanced Materials Technologies, Vol. 4, Issue 9 https://doi.org/10.1002/admt.201900146	journal	June 2019
Nozzle flow behavior of aluminum/polycarbonate composites in the material extrusion printing process: Nozzle flow behavior of aluminum/polycarbonate composites in the material extrusion printing process Zhang, Xinzhou; Chen, Lan; Kowalski, Caleb Journal of Applied Polymer Science, Vol. 136, Issue 12 https://doi.org/10.1002/app.47252	journal	November 2018
Metal Alloys for Fusion-Based Additive Manufacturing Zhang, Duyao; Sun, Shoujin; Qiu, Dong Advanced Engineering Materials, Vol. 20, Issue 5 https://doi.org/10.1002/adem.201700952	journal	February 2018
Effect of SLM Build Parameters on the Compressive Properties of 304L Stainless Steel Fashanu, Okanmisope; Buchely, Mario F.; Spratt, Myranda Journal of Manufacturing and Materials Processing, Vol. 3, Issue 2 https://doi.org/10.3390/jmmp3020043	journal	June 2019
Can Appropriate Thermal Post-Treatment Make Defect Content in as-Built Electron Beam Additively Manufactured Alloy 718 Irrelevant? Goel, Sneha; Bourreau, Kévin; Olsson, Jonas Materials, Vol. 13, Issue 3 https://doi.org/10.3390/ma13030536	journal	January 2020
Post-Processing Improvements for Mechanical, Microstructure, and Surface Properties of Steel Lombardi, Mariangela Metals, Vol. 10, Issue 2 https://doi.org/10.3390/met10020230	journal	February 2020
Effect of Surface and Subsurface Defects on Fatigue Behavior of AlSi10Mg Alloy Processed by Laser Powder Bed Fusion (L-PBF) Hamidi Nasab, Milad; Giussani, Alessandro; Gastaldi, Dario Metals, Vol. 9, Issue 10 https://doi.org/10.3390/met9101063	journal	September 2019
Exploiting Process-Related Advantages of Selective Laser Melting for the Production of High-Manganese Steel Haase, Christian; Bültmann, Jan; Hof, Jan Materials, Vol. 10, Issue 1 https://doi.org/10.3390/ma10010056	journal	January 2017
State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design Dass, Adrita; Moridi, Atieh Coatings, Vol. 9, Issue 7 https://doi.org/10.3390/coatings9070418	journal	June 2019
Surface deformations in dynamic thermocapillary convection under partial slip. Kowal, Katarzyna; Davis, Stephen H.; Voorhees, Peter W. Apollo - University of Cambridge Repository https://doi.org/10.17863/cam.45334	text	January 2019
In Situ 3D Monitoring of Geometric Signatures in the Powder-Bed-Fusion Additive Manufacturing Process via Vision Sensing Methods Li, Zhongwei; Liu, Xingjian; Wen, Shifeng Sensors, Vol. 18, Issue 4 https://doi.org/10.3390/s18041180	journal	April 2018
Effect of Compositional Variation Induced by EBM Processing on Deformation Behavior and Phase Stability of Austenitic Cr-Mn-Ni TRIP Steel Günther, J.; Lehnert, R.; Wagner, R. JOM, Vol. 72, Issue 3 https://doi.org/10.1007/s11837-020-04018-6	journal	January 2020
Simulation of temperature, stress and microstructure fields during laser deposition of Ti-6Al-4V Ghosh, Supriyo; McReynolds, Kevin; Guyer, Jonathan E. arXiv https://doi.org/10.48550/arxiv.1809.01056	text	January 2018
Influence of Process Parameters and Deposition Strategy on Laser Metal Deposition of 316L Powder Mazzucato, Federico; Aversa, Alberta; Doglione, Roberto Metals, Vol. 9, Issue 11 https://doi.org/10.3390/met9111160	journal	October 2019
Anisotropic Mechanical Behavior of AlSi10Mg Parts Produced by Selective Laser Melting Tang, Ming; Pistorius, Petrus Christiaan JOM, Vol. 69, Issue 3 https://doi.org/10.1007/s11837-016-2230-5	journal	January 2017
Mechanical characterisation of stainless steel parts produced by direct metal laser sintering with virgin and reused powder Contaldi, V.; Del Re, F.; Palumbo, B. The International Journal of Advanced Manufacturing Technology, Vol. 105, Issue 7-8 https://doi.org/10.1007/s00170-019-04416-4	journal	November 2019
The Influence of Annealing Temperature and Time on the Formation of δ-Phase in Additively-Manufactured Inconel 625 Stoudt, M. R.; Lass, E. A.; Ng, D. S. Metallurgical and Materials Transactions A, Vol. 49, Issue 7 https://doi.org/10.1007/s11661-018-4643-y	journal	May 2018
Sensor-Based Build Condition Monitoring in Laser Powder Bed Fusion Additive Manufacturing Process Using a Spectral Graph Theoretic Approach Montazeri, Mohammad; Rao, Prahalada Journal of Manufacturing Science and Engineering, Vol. 140, Issue 9 https://doi.org/10.1115/1.4040264	journal	June 2018
Additive Manufacturing of Metallic Materials: A Review Zhang, Yi; Wu, Linmin; Guo, Xingye Journal of Materials Engineering and Performance, Vol. 27, Issue 1 https://doi.org/10.1007/s11665-017-2747-y	journal	May 2017
Additive Techniques to Refurbish Ni Based Components Cardozo, Eloisa Pereira; Pardal, Gonçalo Rodrigues; Ríos, Sergio Soldagem & Inspeção, Vol. 24 https://doi.org/10.1590/0104-9224/si24.03	journal	January 2019
Preparation and properties of copper matrix composite reinforced with SLM Fe alloy lattice Xu, Huiyan; Li, Zhenhua; Teng, Baoren Materials Research Express, Vol. 6, Issue 5 https://doi.org/10.1088/2053-1591/ab0433	journal	February 2019
Additive manufacturing of titanium alloys in the biomedical field: processes, properties and applications Trevisan, Francesco; Calignano, Flaviana; Aversa, Alberta Journal of Applied Biomaterials & Functional Materials, Vol. 16, Issue 2 https://doi.org/10.5301/jabfm.5000371	journal	August 2017
An Overview of Additive Manufacturing of Titanium Components by Directed Energy Deposition: Microstructure and Mechanical Properties Saboori, Abdollah; Gallo, Donato; Biamino, Sara Applied Sciences, Vol. 7, Issue 9 https://doi.org/10.3390/app7090883	journal	August 2017
Process defects and in situ monitoring methods in metal powder bed fusion: a review Grasso, Marco; Colosimo, Bianca Maria Measurement Science and Technology, Vol. 28, Issue 4 https://doi.org/10.1088/1361-6501/aa5c4f	journal	February 2017
Spark Plasma Sintering of Graded Dissimilar Metals Naveen Kumar, N.; Janaki Ram, G. D.; Bhattacharya, S. S. Transactions of the Indian Institute of Metals, Vol. 72, Issue 7 https://doi.org/10.1007/s12666-019-01662-8	journal	April 2019
Optimal Design for Metal Additive Manufacturing: An Integrated Computational Materials Engineering (ICME) Approach Motaman, S. Amir H.; Kies, Fabian; Köhnen, Patrick JOM, Vol. 72, Issue 3 https://doi.org/10.1007/s11837-020-04028-4	journal	January 2020
A Combinatorial Approach for Assessing the Magnetic Properties of High Entropy Alloys: Role of Cr in AlCo _x Cr _{1- x} FeNi : A Combinatorial Approach for Assessing the Magnetic… Borkar, Tushar; Chaudhary, Varun; Gwalani, Bharat Advanced Engineering Materials, Vol. 19, Issue 8 https://doi.org/10.1002/adem.201700048	journal	May 2017
Additive Manufacturing of Titanium Alloys by Electron Beam Melting: A Review Zhang, Lai-Chang; Liu, Yujing; Li, Shujun Advanced Engineering Materials, Vol. 20, Issue 5 https://doi.org/10.1002/adem.201700842	journal	December 2017
Microstructural Investigations in Metals Using Atom Probe Tomography with a Novel Specimen-Electrode Geometry Larson, David J.; Ulfig, Robert M.; Lenz, Dan R. JOM, Vol. 70, Issue 9 https://doi.org/10.1007/s11837-018-2982-1	journal	July 2018
Structural Properties of EB-Welded AlSi10Mg Thin-Walled Pressure Vessels Produced by AM-SLM Technology Nahmany, Moshe; Stern, Adin; Aghion, Eli Journal of Materials Engineering and Performance, Vol. 26, Issue 10 https://doi.org/10.1007/s11665-017-2953-7	journal	September 2017
Effects of Recycled Powder on Solidification Defects, Microstructure, and Corrosion Properties of DMLS Fabricated AlSi10Mg Rafieazad, M.; Chatterjee, A.; Nasiri, A. M. JOM, Vol. 71, Issue 9 https://doi.org/10.1007/s11837-019-03552-2	journal	June 2019
Development of Bulk Metallic Glass Matrix Composites (BMGMC) by Additive Manufacturing: Modelling and Simulation – A Review: Part A Rafique, Muhammad Musaddique Ali; Niezgoda, Stephen; Brandt, Milan Advanced Materials Research, Vol. 1154 https://doi.org/10.4028/www.scientific.net/amr.1154.1	journal	June 2019
Mesoscale design of heterogeneous material systems in multi-material additive manufacturing Garcia, David; Jones, Mackenzie E.; Zhu, Yunhui Journal of Materials Research, Vol. 33, Issue 1 https://doi.org/10.1557/jmr.2017.328	journal	August 2017
Five-Axis Ultrasonic Additive Manufacturing for Nuclear Component Manufacture Hehr, Adam; Wenning, Justin; Terrani, Kurt JOM, Vol. 69, Issue 3 https://doi.org/10.1007/s11837-016-2205-6	journal	December 2016
Predictive modeling of solidification during laser additive manufacturing of nickel superalloys: recent developments, future directions Ghosh, Supriyo Materials Research Express, Vol. 5, Issue 1 https://doi.org/10.1088/2053-1591/aaa04c	journal	January 2018
Effects of Surface Finishing Procedures on Corrosion Behavior of DMLS-AlSi10Mg_200C Alloy Versus Die-Cast A360.1 Aluminum Fathi, P.; Mohammadi, M.; Duan, X. JOM, Vol. 71, Issue 5 https://doi.org/10.1007/s11837-019-03344-8	journal	January 2019
Layerwise Anomaly Detection in Laser Powder-Bed Fusion Metal Additive Manufacturing Mahmoudi, Mohamad; Ezzat, Ahmed Aziz; Elwany, Alaa Journal of Manufacturing Science and Engineering, Vol. 141, Issue 3 https://doi.org/10.1115/1.4042108	journal	January 2019

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