Selective Laser Melting Technology Research Articles

An Investigation on Microstructural Characteristics and Comprehensive Performances of Equiatomic Ratio NiTi Shape‐Memory Alloy Produced by Selective Laser Melting

The present study utilizes selective laser melting (SLM) technology to fabricate NiTi alloy and investigates the deposition quality, microstructure, mechanical performances, and functional properties of the as‐deposited parts. The NiTi component is fabricated by SLM at a suitable energy density (60.61 J cm−3), resulting in favorable surface forming quality and only micron‐sized porosity defects present in the interior. Dense and fine B19’ martensite is distributed within the epitaxial B2 austenite matrix that grows in the height direction through the melt pool boundary, along with the nanoscale Ti2Ni precipitates dispersedly distribute at B19’ grain interiors and grain boundaries. Both tensile and compressive results indicate that the as‐deposited NiTi components acquire slightly inferior ductility but superior strength than that of traditionally manufactured NiTi alloys. The shape‐memory effect of NiTi components is significantly influenced by holding temperature, exhibiting good and stable shape‐memory effect above a holding temperature of 75 °C. Simultaneously, the compressive superelastic behavior of the NiTi component exhibits favorable stability, with a recoverable strain of ≈5.5%. Overall, the NiTi component fabricated in the present study exhibits favorable mechanical properties and functional performance attributed to its excellent deposition quality and dense microstructure.

Optimization design of support structure based on 3D printing technology

Parts are often warped and deformed when they are molded using selective laser melting (SLM) technology. Thus, it is necessary to study the addition support modes of parts molded using SLM. Consequently, we designed dendritic, E-stage and conical supports, having different structural parameters and different partitions using Magics, and then, we analyzed their performances using the finite element software Abaqus. The structural parameters of the supports were optimized and finally tested using SLM molding technology. The maximum stress concentration was found for dendritic supports, followed by E-stage supports, and then conical supports. The stress concentration and deformation level of Scheme 2 were less than those of Scheme 1. The stress intensity and deformation levels for two partitions were less than those for three partitions. For parts molded by SLM, the deformation was maximum for conical supports, followed by dendritic supports, and then E-stage supports. When gradient supports of similar volumes were added, additional partitions did not effectively improve the molding quality. When supports of similar volumes were added, adding gradient supports did not effectively improve the molding quality. The results provide a basis for the application of SLM in molding high-precision parts.

Review of surface metrology artifacts for additive manufacturing

Test artifacts, resembling real machine parts, allow quantitative evaluation of system performance and insight into individual errors, aiding in improvement and standardization in additive manufacturing. The article provides a comprehensive overview of existing test artifacts, categorized based on geometric features and material used. Various measurement techniques such as stylus profilometry and computed tomography are employed to assess these artifacts. It was shown that Selective Laser Melting (SLM) technology and titanium alloys are prevalent in artifact creation. Specific artifact categories include slits, angular aspects, length parameters, variable surfaces, and others, each accompanied by examples from research literature, highlighting diverse artifact designs and their intended applications. The paper critically discusses the main problems with existing geometries. It paper underscores the importance of user-friendly and unambiguous artifacts for dimensional control, particularly in surface metrology. It anticipates the continued growth of metrological verification in future manufacturing environments, emphasizing the need for precise and reliable measurement results to support decision-making in production conditions

Experimental and numerical investigation of heat sinks constructed by anisotropic 3-D Turing patterns

Heat dissipation is a critical issue for various engineering applications such as electronic devices, turbine blades and batteries. Existing heat sink structures contained inherent shortages in geometric flexibility which prevented further development of heat dissipation technologies. This study proposed a self-organized design method for heat sinks inspired by Turing Patterns (TP) in nature morphogenesis. The biomimetic structures were parametrically controlled with the aid of reaction-diffusion equations in terms of feature size, feature density, structural morphology and structural orientation. The metallic selective laser melting (SLM) technology was adopted to fabricate the three-dimensional (3-D) heat sinks. Experimental and numerical evaluations were conducted to compare TP structures with traditional pin-fin (PF) arrays baselines. Results showed substantial advantages of the TP structures in regulating flow field and enhancing height-wise fluid mixing. The thermal performance factor (TPF) of TP structures is approximately 45 % higher than traditional PF structures with similar feature sizes. The globally averaged magnitude of height-wise velocities of TP structure is around 2.4 times larger than that of PF structures due to the existence of the threshold-like and bridge-like structures. With the aid of three-dimensional structures, full utilization of the coolant was achieved to further increase the heat transfer intensity, while a high synergic level was formed within the flow field and temperature field to reduce the pressure drop. The design method proposed in this study demonstrated strong capability in tuning three-dimensional flow field and is expected to provide new insights to the heat transfer area that faces nonuniform thermal conditions and inhomogeneous flow conditions.

Microstructure and mechanical properties of 316L stainless steel manufactured by multi-laser selective laser melting (SLM)

The microstructure and mechanical properties of 316L stainless steel samples manufactured by dual-laser selective laser melting technology, were investigated in compare with that of the single-laser scanning samples. It was found that the porosity of the dual-laser overlap samples was lower than that of single laser forming samples due to the different laser energy density absorbed by the powders. Furthermore, it was found that the crystal structure and crystal orientation of both zones were similar. From the TEM observation, it was noted that the number density of nano-oxides in the overlap zone was higher than that in the single laser forming zone. This reason was suggested as the difference of the oxygen content inside the melt pool during the forming process. The strength and microhardness of the single-laser samples was lower than that of the dual-laser overlap samples, but the elongation was higher. By analyzing the strengthening mechanism, it was revealed that Orowan strengthening was the main reason for the difference. These results could guide the large-size component manufactured using the muti-laser selective laser melting technology.

Research on mechanical properties of lattice structure based on selective laser melting technology

Research on mechanical properties of lattice structure based on selective laser melting technology

Enhanced thermoelectric properties of 3D printed Bi2Te2.7Se0.3 by atomic interface engineering

The performance of n-type Bi2Te3 materials prepared by selective laser melting (SLM) 3D printing technology tends to be lower than p-type materials. Herein, a bottom-up interface engineering strategy based on Atomic Layer Deposition (ALD) is presented to improve the properties of n-type Bi2Te2.7Se0.3 (BTS) materials prepared by SLM. To validate this strategy, a ZnO ultrathin layer was applied to the grain boundaries of BTS, synergistically optimizing carrier/phonon transport. In terms of electrical transport, the energy filtering effect triggered by the constructed ZnO/BTS interface effectively enhances the Seebeck coefficient of the Bi2Te3 material printed by SLM, substantially increasing the power factor. Additionally, the high thermal stability of the ALD-deposited ZnO ultrathin layer effectively suppresses the volatilization of Te in BTS, regulating the carrier concentration. Regarding thermal transport properties, the multiscale defects introduced by the non-equilibrium solidification process during SLM printing cause effective phonon scattering across a wide frequency range, which in turn reduces the thermal conductivity of the material. Atomic-level interface modification in SLM-printed BTS enhanced the ZT value to 1.25. Exploiting this superior thermoelectric performance, a thermoelectric module was constructed. It demonstrated a conversion efficiency of 5.7 % with a temperature difference of 200 K, comparable to the advanced Bi2Te3-based thermoelectric modules. The integration of an ALD interface modification strategy with SLM technology has not only demonstrated potential applications in Bi2Te3-based thermoelectric material development, but also bears significant importance for the accelerated advancement of high-performance thermoelectric materials in other systems.

Effect of laser process parameters on the pores, surface roughness, and hardness of laser selective melting of dental cobalt-chrome alloys.

To address the quality problems caused by high porosity in the preparation of dental cobalt-chrome alloy prosthetics based on selective laser melting (SLM) technology, we investigated the influence mechanism of different forming process parameters on the microstructure and properties of the materials. Moreover, the range of forming process parameters that can effectively reduce defects was precisely defined. The effects of laser power, scanning speed, and scanning distance on the pore properties, surface roughness, and hardness of dental cobalt-chrome alloy were investigated by adjusting the printing parameters in the process of SLM. Through metallographic analysis, image analysis, and molten pool simulation, the pore formation mechanism was revealed, and the relationship between the porosity and energy density of SLM dental cobalt-chrome alloy was elucidated. When the linear energy density was higher than 0.18 J/mm, the porosity defect easily appeared at the bottom of the molten pool. When the laser energy density was lower than 0.13 J/mm, defects occurred in the gap of the molten pool due to insufficient melting of powder. In particular, when the linear energy density exceeded the threshold of 0.30 J/mm or was below 0.12 J/mm, the porosity increased significantly to more than 1%. In addition, we observed a negative correlation between free surface roughness and energy density and an inverse relationship between macroscopic hardness and porosity. On the basis of the conditions of raw materials and molding equipment used in this study, the key process parameters of SLM of molding parts with porosity lower than 1% were successfully determined. Specifically, these key parameters included the line energy density, which ranged from 0.13 J/mm to 0.30 J/mm, and the scan spacing should be strictly controlled below 90 μm.

Influence of annealing treatment on grain growth, texture and magnetic properties of a selective laser melted Fe-6.5 wt% Si alloy

The high-density Fe-6.5 wt% Si soft magnetic alloy samples were prepared using selective laser melting (SLM) technology. Annealing treatments with different temperatures were employed to promote grain growth. The microstructure, texture and magnetic hysteresis loops were characterized, aiming to investigate the relationship between microstructure and magnetic properties. The as-printed Fe-6.5 wt% Si alloy had weak texture and low density of ordered phases, and was featured by coarse grains in the top-view section and columnar grains in the side-view section. After annealing at 800 °C–1000 °C, the textures were slightly weakened, while the grain growth was not significant. Increasing the annealing temperature to 1100 °C led to abnormal grain growth behaviors. The grains of the as-printed Fe-6.5 wt% Si alloy showed randomly abnormal growth behaviors rather than oriented growth, which may be related to the low stored energy and initial size advantage before annealing. After annealed at 1100 °C for 1 h, the abnormal grain growth and the formation of large Goss ({110}<001>) and Cube ({100}<001>) grains resulted in microstructure coarsening and texture optimization. Thus, the corresponding ring-shaped sample exhibited excellent magnetic performance. The magnetic induction B8 is 1.21 T, the maximum relative permeability is 14.71 × 103 and the core loss P10/50 is 11.69 W/kg.

Controlled Porosity of Selective Laser Melting-Produced Thermal Pipes: Experimental Analysis and Machine Learning Approach for Pore Recognition on Pipes Surfaces.

This study investigates the methods for controlling porosity in thermal pipes manufactured using selective laser melting (SLM) technology. Experiments conducted include water permeability tests and surface roughness measurements, which are complemented by SEM image ML-based analysis for pore recognition. The results elucidate the impact of SLM printing parameters on water permeability. Specifically, an increase in hatch and point distances leads to a linear rise in permeability, while higher laser power diminishes permeability. Using machine learning (ML) techniques, precise pore identification on SEM images depicting surface microstructures of the samples is achieved. The average percentage of the surface area containing detected pores for microstructure samples printed with laser parameters (laser power (W) _ hatch distance (µm) _ point distance (µm)) 175_ 80_80 was found to be 5.2%, while for 225_120_120, it was 4.2%, and for 275_160_160, it was 3.8%. Pore recognition was conducted using the Haar feature-based method, and the optimal patch size was determined to be 36 pixels on monochrome images of microstructures with a magnification of 33×, which were acquired using a Leica S9 D microscope.

Nanoindentation Creep Behavior of Additively Manufactured H13 Steel by Utilizing Selective Laser Melting Technology.

Nowadays, H13 hot work steel is a commonly used hot work die material in the industry; however, its creep behavior for additively manufactured H13 steel parts has not been widely investigated. This research paper examines the impact of volumetric energy density (VED), a critical parameter in additive manufacturing (AM), and the effect of post heat-treatment nitrification on the creep behavior of H13 hot work tool steel, which is constructed through selective laser melting (SLM), which is a powder bed fusion process according to ISO/ASTM 52900:2021. The study utilizes nanoindentation tests to investigate the creep response and the associated parameters such as the steady-state creep strain rate. Measurements and observations taken during the holding phase offer a valuable understanding of the behavior of the studied material. The findings of this study highlight a substantial influence of both VED and nitrification on several factors including hardness, modulus of elasticity, indentation depth, and creep displacement. Interestingly, the creep strain rate appears to be largely unaltered by these parameters. The study concludes with the observation that the creep stress exponent (n) shows a decreasing trend with an increase in VED and the application of nitrification treatment.

Influence of heat treatment on microstructure and tensile properties of selective laser melting metastable Ti55531-0.5Nb alloy

The deposition of metastable titanium alloys using additive manufacturing techniques is of increasing interest. The as-build samples generally require further subsequent heat treatment to control the microstructure and to meet the good comprehensive performance of structural components. In this study, the Ti55531-0.5Nb alloys fabricated by selective laser melting (SLM) technology after solution treatment were cooled in different modes to investigate the effect of cooling rates on microstructural evolution and tensile properties. The results indicate that the volume fraction of primary α decreases with the increase of cooling rate, while the secondary α displays the opposite trend. The high cooling rates increase the residual stresses in the sample, providing an additional driving force for phase precipitation during the aging process. In addition, all samples with different cooling rates exhibited high elongation (>10 %). The difference is that the Ti55531-0.5Nb alloys are more sensitive to changes in elongation than ultimate tensile strength (UTS) with variations in cooling rates. The UTS and elongation of the sample with solution plus water cooling and aging (STWC+AG) are 1185 ± 9 MPa and 10.3 ± 0.3 %, respectively, while the furnace cooling and aging (STFC+AG) sample exhibits a 71.4 % improvement in elongation at the expense of the UTS of 13.8 %. Furthermore, the fracture behavior of the samples exhibited a mixed fracture mechanism dominated by ductile fracture, and the ductile fracture is more prominent with the cooling rate decreases. The microscale shear band contributing to the elongation was found in the shear lip zone for the low cooling rate.

Experimental investigation and optimization of the effects of manufacturing parameters on geometric tolerances in additive manufacturing of AlSi10Mg alloy

While the quality of parts produced by additive manufacturing is generally evaluated by surface roughness, relative density, and mechanical properties, the issue of dimensional accuracy is not examined sufficiently. However, dimensional accuracy is very important for the final use and finishing of a product. Since the dimensional change mainly occurs due to shrinkage resulting from the heat energy applied during the sintering process, the effect of production parameters in the additive manufacturing method is quite large. To minimize shrinkage and increase dimensional accuracy, manufacturing parameters need to be optimized and meticulously examined. This study was aimed at determining the effects of manufacturing parameters on geometric tolerances in the production of parts using the additive manufacturing method. AlSi10Mg powder alloy and selective laser melting (SLM) technology were used in the additive manufacturing of this alloy in part production. Twelve different laser powers and scanning speeds, as well as fixed scanning range and layer thickness parameters, were used in production. In determining geometric tolerances, features such as hole diameter change, deviation from angularity, deviation from perpendicularity, deviation from flatness, and deviation from parallelism were taken into consideration. As a result of the study, deviation values increased in high and low laser power/scanning speed combinations. Minimum deviation amounts were obtained in the range of 250–310 laser power and 785–974 scanning speed, which are the middle values of the parameters used. The optimum values of different output responses have been obtained with different production parameters, but for the final use and quality control approval of the product, it is necessary to determine the input parameters at which all output responses are optimal. In this process, the gray relational analysis optimization method, which is one of the multi-criteria decision-making methods, was preferred. As a result of the optimization, the optimum manufacturing parameters for geometric tolerances were determined as the 290/911 laser power/scanning speed combination.

In-situ tensile testing of fracture and strain in a selective laser melted AlSi10Mg alloy

The melt pools, the most basic units of the components fabricated by the selective laser melting (SLM) technology, play an important role in the mechanical properties of the structures. A self-developed in-situ tensile observation platform was used to carry out the in-situ tensile test of SLMed AlSi10Mg alloy specimens under the observation of optical microscope. With a series of obtained experimental data on mechanical properties and metallurgical images, combined with the digital image correlation(DIC) technology, the melt pool of the specimen and the strain of defects were analyzed, and the deformation and fracture mechanism of the SLMed AlSi10Mg alloy specimens was obtained. The results show that the proposed method successfully obtains the deformation field evolution data of the melt pool and defects, which provides experimental and theoretical support for the further study of crack extension characteristics and fatigue life prediction of SLMed metallic material components.

Investigating mechanical properties of 3D printed porous titanium scaffolds for bone tissue engineering

Objective. Three-dimensional (3D) printed porous titanium scaffolds serve as a bone tissue engineering technology that offers a promising solution for addressing bone defects. The scaffold’s pore structure offers structural support and facilitates the proliferation of bone cells. Therefore, investigating the aperture and pore shape is of crucial for the development of 3D printed porous titanium scaffolds. Methods. Ti6Al4V scaffolds with the specified structure were fabricated using selective laser melting (SLM) technology. The scaffolds comprised fifteen cylindrical models measuring 20 mm in diameter and 20 mm in height. These models featured five scaffold shapes: imitation diamond-60°, imitation diamond-90°, imitation diamond-120°, regular tetrahedron and regular hexahedron. Each of these structural shapes was characterized by three different aperture sizes (400 μm, 600 μm and 800 μm). The porosity and mechanical properties of Ti6Al4V scaffolds were examined. Results. The measured porosity of Ti6Al4V scaffolds varied between 56.50% and 95.28%. The porosity increased with the size of the aperture. The mechanical properties tests revealed that, for identical apertures, the compressive strength and torsional strength were influenced by the configuration of the unit structure. Furthermore, the positive and lateral compressive strength as well as torsional strength of various unit structures exhibited distinct advantages and disadvantages. Within a uniform unit structure shape, the compressive strength and torsional strength were found to be correlated with the size of apertures, indicating that larger apertures result in decreased compressive and torsional strength. Conclusion. The configuration of the aperture and the shape of the pore were identified as significant factors that influenced the compressive strength. The compressive strength of Ti6Al4V scaffolds with various unit structure shapes exhibited both advantages and disadvantages when subjected to positive, lateral, and torsional forces. The enlarged aperture augmented the scaffold’s porosity while diminishing its compressive and torsional strength.

A Review of the Vaporization Behavior of Some Metal Elements in the LPBF Process.

Metal additive manufacturing technology has developed by leaps and bounds in recent years; selective laser melting technology is a major form in metal additive manufacturing, and its application scenarios are numerous. For example, it is involved in many fields including aerospace field, automotive, mechanical processing, and the nuclear industry. At the same time, it also indirectly provides more raw materials for all walks of life in our country. However, during the selective laser melting process, due to the action of high-energy-density lasers, the temperature of most metal powders can reach above the vaporization temperature. Light metals with relatively low vaporization temperatures such as magnesium and zinc have more significant vaporization and other behaviors. At the same time, during the metal vaporization process, a variety of by-products are generated, which seriously affect the forming quality and mechanical properties of the workpiece, resulting in the workpiece quality possibly not reaching the expected target. This paper mainly interprets the metal vaporization behavior in the LPBF process and summarizes the international research progress and suppression methods for vaporization.

Analysis of printing time components and powder utilisation efficiency of metal selective laser melting process in case of 316L and Ti6Al4V materials

ABSTRACT In selective laser melting technology, the productivity and the efficiency of powder utilisation were examined. Individual components of the printing time were determined by developing a specially designed model. Two main components of the powder recoating and the laser exposure time were given as a function of the filling ratio of the cross-section. Based on the results, the spreading time can increase the printing time by several hours, depending on the filling factor of the cross-section. In the case of a sampling of 70 prints, the individual elements and process of the powder usage were determined, as well as the mass measurement of the different amounts of powder in the case of 316L and Ti6Al4V materials. It turned out that 45–80% of the powder amount is not used to build the model, which is an essential for both printer users and equipment developers for material cost prediction.

Design, fabrication, and clinical characterization of additively manufactured tantalum hip joint prosthesis

Abstract The joint prosthesis plays a vital role in the outcome of total hip arthroplasty. The key factors that determine the performance of joint prostheses are the materials used and the structural design of the prosthesis. This study aimed to fabricate a porous tantalum (Ta) hip prosthesis using selective laser melting (SLM) technology. The feasibility of SLM Ta use in hip prosthesis was verified by studying its chemical composition, metallographic structure, and mechanical properties. In vitro experiments proved that SLM Ta exhibited better biological activities in promoting osteogenesis and inhibiting inflammation than SLM Ti6Al4V. Then, the topological optimization design of the femoral stem of the SLM Ta hip prosthesis was carried out by finite element simulation, and the fatigue performance of the optimized prosthesis was tested to verify the biomechanical safety of the prosthesis. A porous Ta acetabulum cup was also designed and fabricated using SLM. Its mechanical properties were then studied. Finally, clinical trials were conducted to verify the clinical efficacy of the SLM Ta hip prosthesis. The porous structure could reduce the weight of the prosthesis and stress shielding and avoid bone resorption around the prosthesis. In addition, anti-infection drugs can also be loaded into the pores for infection treatment. The acetabular cup can be custom-designed based on the severity of bone loss on the acetabular side, and the integrated acetabular cup can repair the acetabular bone defect while achieving the function of the acetabular cup.

Effect of vacuum infiltration temperature on the microstructure and tribological properties of honeycomb-filled tube-reinforced aluminum matrix composites

The purpose of this work is to optimize the penetration temperature to obtain 316 L honeycomb-filled tube/aluminum matrix composite (HFT/AMC) with good wear resistance. Utilized selective laser melting technology to fabricate honeycomb-filled tubes as reinforcement for the composite material. HFT/AMC was prepared by filling aluminum into honeycomb-filled tubes under three different temperatures of 800 °C, 850 °C, and 900 °C through vacuum infiltration casting. And performed tissue characterization and performance testing. Microstructure, hardness, XRD, and EDS studies showed that the composite materials generate intermetallic compound transition layers of over 100 μm, and the overall strength of the interface was improved. A large number of intermetallic compounds and honeycomb-filled tubes distributed in the aluminum matrix inside the cells jointly strengthen the aluminum-based material. Inspection of worn surfaces of HFT/AMCs revealed abrasive and oxidative wear as the main wear mechanisms. Considering the wear of the produced HFT/AMC under certain conditions, the most suitable infiltration temperature is 850 °C (wear rate: 0.52 ± 0.16 [(mm3/N·m) × 10−3]). This study confirmed that honeycomb-filled tubes can significantly improve the tribological properties of aluminum-based materials.

The Influence of Additively Manufactured Specimen Thickness on Laser-Induced Ultrasonic Signals

Selective laser melting (SLM) technology, employed in metal additive manufacturing, is widely utilised to fabricate components with precise dimensions and excellent mechanical properties by melting powder layer by layer. Laser ultrasonic testing is anticipated to be an efficient method for in-line monitoring in the additive manufacturing (AM) process. The conversion of specimens from thin to thick during the SLM manufacturing process has an impact on the ultrasonic signals. This paper focuses on the influence of AM specimen thickness changes on ultrasonic signals. In the finite element analysis, the incremental specimen thickness was maintained at 0.2 mm, which was the initial value. As the specimen thickness increased sequentially, ultrasonic signals were obtained from different specimens. The results demonstrate that Lamb waves are generated when the specimen is thin, and the dispersive characteristics weaken as the thickness increases. The dispersive phenomenon diminishes significantly once the specimen thickness exceeds 1 mm. By employing the f-k method, calculated dispersion curves for various specimen thicknesses were obtained. After fitting the derived dispersion curve, a mapping relationship is established with respect to the specimen thickness. Consequently, the fitting coefficient of the dispersion curve can therefore be utilized to characterize the thickness of the additive manufactured thin specimen.