Abstract
Metal matrix composites (MMCs) present extraordinary characteristics, including high wear resistance, excellent operational properties at elevated temperature, and better chemical inertness as compared to traditional alloys. These properties make them prospective candidates in the fields of aerospace, automotive, heavy goods vehicles, electrical, and biomedical industries. MMCs are challenging to process via traditional manufacturing techniques, requiring high cost and energy. The laser-melting deposition (LMD) has recently been used to manufacture MMCs via rapid prototyping, thus, solving these drawbacks. Besides the benefits mentioned above, the issues such as lower ultimate tensile strength, yield strength, weak bonding between matrix and reinforcements, and cracking are still prevalent in parts produced by LMD. In this article, a detailed analysis is made on the MMCs manufactured via LMD. An illustration is presented on the LMD working principle, its classification, and dependent and independent process parameters. Moreover, a brief comparison between the wire and powder-based LMDs has been summarized. Ex- and in-situ MMCs and their preparation techniques are discussed. Besides this, various matrices available for MMCs manufacturing, properties of MMCs after printing, possible complications and future research directions are reviewed and summarized.
Highlights
Additive manufacturing, abbreviated as AM, is the reverse of subtractive manufacturing technologies and defined by ASTM F2792 as “a procedure of joining the materials usually layer by layer to form 3D objects using a computer aided design (CAD) model” [1]
Mechanical tests were carried out; the results showed that the addition of Al2 O3 -nanoparticles (0–14 wt.%) within Ti-matrix could exponentially increase the hardness from 100 HV to 650 HV
Laser-Melting Deposition (LMD) process, depending on the experimental setup can be classified into three sub-categories: (a) direct metal deposition (DMD), (b) laser-engineered net-shaping (LENS), and (c) direct light fabrication (DLF)
Summary
Additive manufacturing, abbreviated as AM, is the reverse of subtractive manufacturing technologies and defined by ASTM F2792 as “a procedure of joining the materials usually layer by layer to form 3D objects using a computer aided design (CAD) model” [1]. They can be classified into two major categories: direct- and indirect-AM methods [2]. Parts with higher density, purity, and excellent mechanical properties can be produced with less energy and time in comparison to indirect-AM processes [2,3,4,5]. Indirect-AM processes are mainly composed of green bodies and binder materials, which are mixed to manufacture a 3D structure. The process is followed by a sintering process to eliminate the binder material. In the end, they are densified by conventional manufacturing processes [2].
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