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

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.

View Accepted Manuscript (DOE)

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

Publisher:: Taylor & FrancisCopyright Statement

Country of Publication:: United States

Language:: English

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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
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
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
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
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
A Metallographic Review of 3D Printing/Additive Manufacturing of Metal and Alloy Products and Components Murr, L. E. Metallography, Microstructure, and Analysis, Vol. 7, Issue 2 https://doi.org/10.1007/s13632-018-0433-6	journal	March 2018
Direct metal additive manufacturing processes and their sustainable applications for green technology: A review Ahn, Dong-Gyu International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 3, Issue 4 https://doi.org/10.1007/s40684-016-0048-9	journal	October 2016
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
Tensile lap-shear and flexural behaviour of aluminium metal foil parts made by composite metal foil manufacturing Butt, Javaid; Mebrahtu, Habtom; Shirvani, Hassan Progress in Additive Manufacturing, Vol. 4, Issue 2 https://doi.org/10.1007/s40964-018-0060-4	journal	August 2018
Characterization of mechanical properties and fracture mode of PLA and copper/PLA composite part manufactured by fused deposition modeling Zhang, Xinzhou; Chen, Lan; Mulholland, Tom SN Applied Sciences, Vol. 1, Issue 6 https://doi.org/10.1007/s42452-019-0639-5	journal	May 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
The role of side-branching in microstructure development in laser powder-bed fusion Pham, Minh-Son; Dovgyy, Bogdan; Hooper, Paul A. Nature Communications, Vol. 11, Issue 1 https://doi.org/10.1038/s41467-020-14453-3	journal	February 2020
Spall fracture in additive manufactured tantalum Jones, D. R.; Fensin, S. J.; Ndefru, B. G. Journal of Applied Physics, Vol. 124, Issue 22 https://doi.org/10.1063/1.5063930	journal	December 2018
The impact of powder oxygen content on formability of 12CrNi2 alloy steel fabricated by laser melting deposition Cui, X.; Zhang, S.; Zhang, C. H. Powder Metallurgy, Vol. 62, Issue 3 https://doi.org/10.1080/00325899.2019.1616367	journal	May 2019
Influence of energy density on metallurgy and properties in metal additive manufacturing Yusuf, Shahir M.; Gao, Nong Materials Science and Technology, Vol. 33, Issue 11 https://doi.org/10.1080/02670836.2017.1289444	journal	February 2017
Modelling of selective laser melting process with adaptive remeshing Khan, K.; De, A. Science and Technology of Welding and Joining, Vol. 24, Issue 5 https://doi.org/10.1080/13621718.2019.1575057	journal	February 2019
On the use of metastable interface equilibrium assumptions on prediction of solidification micro-segregation in laser powder bed fusion Abreu Faria, Guilherme; Kadirvel, Kamalnath; Hinojos, Alejandro Science and Technology of Welding and Joining, Vol. 24, Issue 5 https://doi.org/10.1080/13621718.2019.1608406	journal	April 2019
Toward the digital twin of additive manufacturing: Integrating thermal simulations, sensing, and analytics to detect process faults Gaikwad, Aniruddha; Yavari, Reza; Montazeri, Mohammad IISE Transactions, Vol. 52, Issue 11 https://doi.org/10.1080/24725854.2019.1701753	journal	January 2020
Evolution of molten pool during selective laser melting of Ti–6Al–4V Zhang, Tao; Li, Hui; Liu, Sheng Journal of Physics D: Applied Physics, Vol. 52, Issue 5 https://doi.org/10.1088/1361-6463/aaee04	journal	November 2018
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
On the primary spacing and microsegregation of cellular dendrites in laser deposited Ni–Nb alloys Ghosh, Supriyo; Ma, Li; Ofori-Opoku, Nana Modelling and Simulation in Materials Science and Engineering, Vol. 25, Issue 6 https://doi.org/10.1088/1361-651x/aa7369	journal	June 2017
Simulation of temperature, stress and microstructure fields during laser deposition of Ti–6Al–4V Ghosh, Supriyo; McReynolds, Kevin; Guyer, Jonathan E. Modelling and Simulation in Materials Science and Engineering, Vol. 26, Issue 7 https://doi.org/10.1088/1361-651x/aadff2	journal	September 2018
Residual stress measurements of laser metal deposited Ti-6Al-4V parts using neutron diffraction Em, V. T.; Ivanov, S. Y.; Karpov, I. D. Journal of Physics: Conference Series, Vol. 1109 https://doi.org/10.1088/1742-6596/1109/1/012049	journal	November 2018
Laser induced breakdown spectroscopy for in-situ multielemental analysis during additive manufacturing process Lednev, V. N.; Tretyakov, R. S.; Sdvizhenskii, P. A. Journal of Physics: Conference Series, Vol. 1109 https://doi.org/10.1088/1742-6596/1109/1/012050	journal	November 2018
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
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
Ultrafast X-ray imaging of laser–metal additive manufacturing processes Parab, Niranjan D.; Zhao, Cang; Cunningham, Ross Journal of Synchrotron Radiation, Vol. 25, Issue 5 https://doi.org/10.1107/s1600577518009554	journal	August 2018
Rapid fabrication of ion optics by selective laser melting Sangregorio, Miguel; Wang, Ningfei; Xie, Kan Rapid Prototyping Journal, Vol. 25, Issue 2 https://doi.org/10.1108/rpj-05-2017-0085	journal	March 2019
Fatigue behaviors of laser hybrid welded AA7020 due to defects via synchrotron X‐ray microtomography Wu, Sheng‐Chuan; Hu, Ya‐Nan; Song, Zhe Fatigue & Fracture of Engineering Materials & Structures, Vol. 42, Issue 10 https://doi.org/10.1111/ffe.13031	journal	June 2019
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
In-Process Monitoring of Material Cross-Contamination Defects in Laser Powder Bed Fusion Montazeri, Mohammad; Yavari, Reza; Rao, Prahalada Journal of Manufacturing Science and Engineering, Vol. 140, Issue 11 https://doi.org/10.1115/1.4040543	journal	July 2018
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
Influence of Si Content on the Microstructure and Corrosion Behavior of Additive Manufactured Al-Si Alloys Revilla, Reynier I.; De Graeve, Iris Journal of The Electrochemical Society, Vol. 165, Issue 13 https://doi.org/10.1149/2.0101814jes	journal	January 2018
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
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
Effect of Compositional Variation Induced by EBM Processing on Deformation Behavior and Phase Stability of Austenitic Cr-Mn-Ni TRIP Steel Günther, Johannes; Lehnert, Robert; Wagner, Ruben Universität Kassel https://doi.org/10.17170/kobra-202005041208	text	January 2020
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
Mechanical Properties of High-Speed Steel AISI M50 Produced by Laser Powder Bed Fusion Kunz, Johannes; Saewe, Jasmin; Herzog, Simone RWTH Aachen University https://doi.org/10.18154/rwth-2020-01732	text	January 2019
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
Application of Directed Energy Deposition-Based Additive Manufacturing in Repair Saboori, Abdollah; Aversa, Alberta; Marchese, Giulio Applied Sciences, Vol. 9, Issue 16 https://doi.org/10.3390/app9163316	journal	August 2019
Processing of Alnico Magnets by Additive Manufacturing White, Emma; Rinko, Emily; Prost, Timothy Applied Sciences, Vol. 9, Issue 22 https://doi.org/10.3390/app9224843	journal	November 2019
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
Additive Manufacturing, Cloud-Based 3D Printing and Associated Services—Overview Baumann, Felix; Roller, Dieter Journal of Manufacturing and Materials Processing, Vol. 1, Issue 2 https://doi.org/10.3390/jmmp1020015	journal	October 2017
Effect of Build Orientation on the Microstructure and Mechanical Properties of Selective Laser-Melted Ti-6Al-4V Alloy Hartunian, Patrick; Eshraghi, Mohsen Journal of Manufacturing and Materials Processing, Vol. 2, Issue 4 https://doi.org/10.3390/jmmp2040069	journal	October 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
Metal Additive Manufacturing Cycle in Aerospace Industry: A Comprehensive Review Barroqueiro, B.; Andrade-Campos, A.; Valente, R. A. F. Journal of Manufacturing and Materials Processing, Vol. 3, Issue 3 https://doi.org/10.3390/jmmp3030052	journal	June 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
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
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
Investigation on Porosity and Microhardness of 316L Stainless Steel Fabricated by Selective Laser Melting Yusuf, Shahir; Chen, Yifei; Boardman, Richard Metals, Vol. 7, Issue 2 https://doi.org/10.3390/met7020064	journal	February 2017
Effects of Platform Pre-Heating and Thermal-Treatment Strategies on Properties of AlSi10Mg Alloy Processed by Selective Laser Melting Casati, Riccardo; Hamidi Nasab, Milad; Coduri, Mauro Metals, Vol. 8, Issue 11 https://doi.org/10.3390/met8110954	journal	November 2018
Wear and Cavitation Erosion Resistance of an AlMgSc Alloy Produced by DMLS Tocci, Marialaura; Pola, Annalisa; Girelli, Luca Metals, Vol. 9, Issue 3 https://doi.org/10.3390/met9030308	journal	March 2019
3D Printed Acetabular Cups for Total Hip Arthroplasty: A Review Article No authors listed Metals, Vol. 9, Issue 7 https://doi.org/10.3390/met9070729	journal	June 2019
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
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
Evaluation of Support Structure Removability for Additively Manufactured Ti6Al4V Overhangs via Electron Beam Melting Ameen, Wadea; Khan Mohammed, Muneer; Al-Ahmari, Abdulrahman Metals, Vol. 9, Issue 11 https://doi.org/10.3390/met9111211	journal	November 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
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
Single-Track Melt-Pool Measurements and Microstructures in Inconel 625 Ghosh, Supriyo; Ma, Li; Levine, Lyle E. arXiv https://doi.org/10.48550/arxiv.1802.05827	text	January 2018
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
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

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