Differences in microstructure and properties between selective laser melting and traditional manufacturing for fabrication of metal parts: A review

doi:10.1007/s11465-015-0341-2

Front. Mech. Eng.

2015, Vol. 10

Issue (2) : 111-125 https://doi.org/10.1007/s11465-015-0341-2

REVIEW ARTICLE

Differences in microstructure and properties between selective laser melting and traditional manufacturing for fabrication of metal parts: A review

Bo SONG, Xiao ZHAO, Shuai LI, Changjun HAN, Qingsong WEI(

), Shifeng WEN, Jie LIU, Yusheng SHI

State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China

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Abstract

Selective laser melting (SLM), as one of the additive manufacturing technologies, is widely investigated to fabricate metal parts. In SLM, parts are manufactured directly from powders in a layer-by-layer fashion; SLM also provides several advantages, such as production of complex parts with high three-dimensional accuracy, compared with other additive manufacturing technologies. Therefore, SLM can be applied in aeronautics, astronautics, medicine, and die and mould industry. However, this technique differs from traditional methods, such as casting and forging; for instance, the former greatly differs in terms of microstructure and properties of products. This paper summarizes relevant studies on metal material fabrication through SLM. Based on a work completed in Huazhong Univ. Sci Tech., Rapid Manuf. Center (HUST-RMC) and compared with characteristics described in other reported studies, microstructure, properties, dimensional accuracy, and application of SLM are presented.

Keywords selective laser melting microstructure performance application

Corresponding Author(s): Qingsong WEI

Issue Date: 14 July 2015

Cite this article:

Bo SONG,Xiao ZHAO,Shuai LI, et al. Differences in microstructure and properties between selective laser melting and traditional manufacturing for fabrication of metal parts: A review[J]. Front. Mech. Eng., 2015, 10(2): 111-125.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-015-0341-2
https://academic.hep.com.cn/fme/EN/Y2015/V10/I2/111

Fig.1 SEM images of MPBs in the SLM samples. (a) MPBs on the cross section parallel to the laser scanning direction [7]; (b) morphology of the cross section perpendicular to the scanning direction; (c) “track-track” MPB morphology [2]

Fig.2 Microstructures of the different materials fabricated by SLM. (a) Ti-6Al-4V [11]; (b) Fe/SiC [16]

Fig.3 Tensile fracture morphologies of the sample fabricated along the direction (a) perpendicular to the laser scanning direction and (b) with an angle of 60° between the tensile loading direction and the x-y plane [2]

Fig.4 (a) Schematic of the scanning strategy; (b) electron back-scattered diffraction (EBSD) orientation maps of the inverse pole LPF and reference coordinate of the bidirectional-samples; (c) inverse pole LPF and map (100) of the Robi-directional-samples

Fig.5 Typical defects of the SLM parts: (a) Porosity, (b) cracks

Fig.6 Ni625 fabricated by SLM. (a) Cracks observed by SEM; (b) cracks observed by EBSD; (c) SEM image with energy dispersive spectrometer results (the unit is wt.%)

Fig.7 Ti–6A-l4V alloy fabricated by SLM. (a) Cracks observed by SEM; (b) facture morphology observed by SEM

Tab.1 Static properties of the SLM-processed and wrought alloys (Young’s modulus, E, and Poission’s ratio, P)

Fig.8 Fatigue results of SLM processed Ti-6Al-4V (

R = − 0.2

, K_t=1.0) [65]

Fig.9 Surface morphology of the part fabricated by SLM. (a) Top view, (b) cross section view [66]

Fig.10 3D measurement for the part fabricated by SLM

Fig.11 Parts fabricated by SLM in HUST-RMC

Fig.12 Rocket nozzle parts of superalloy fabricated by NASA [82]

Fig.13 Complex mould block with conformal cooling channels fabricated by SLM

Fig.14 Porous structures fabricated by traditional methods: (a) Casting, (b) vapor deposition, (c) spraying, and (d) sintered powder

Fig.15 3D image of porous scaffolds using micro-CT and (b) the two-dimensional image of pores

Fig.16 Porous 316L parts with complex space fabricated by SLM in HUST-RMC

Fig.17 (a) Metal denture model fabricated by SLM and (b) after porcelain

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