Print

2022 №11 (01) DOI of Article
10.37434/tpwj2022.11.02
2022 №11 (03)

The Paton Welding Journal 2022 #11
The Paton Welding Journal, 2022, #11, 8-16 pages

Problems and prospects of studying the processes of selective laser melting of materials for aerospace engineering (Review)

M.V. Sokolovskyi

E.O. Paton Electric Welding Institute of the NASU. 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: m_sokolovskyi@paton.kiev.ua

Abstract
n this work in order to determine the relevant directions of research of different scientific components of the process of selective laser melting (SLM), as well as technological measures affecting the final structure, mechanical and service characteristics of a manufactured part, a literary review of the materials was made devoted to different directions of research of SLM technology. The directions of scientific works considered in this review were: research and deepening knowledge on the influence of the energy component of SLM process; possibilities of SLM process modification by the control of laser focus value; study of modes and methods of SLM processing as well as final microstructure of samples; study of corrosion resistance of products, manufactured using SLM. Based on the results of the literary analysis, the problems and prospects of studying SLM processes for materials of aerospace industry are shown, the need in creating a systematic comprehensive approach to the study of the components of SLM process, as well as deepening knowledge about the technological capabilities of its use. 46 Ref., 6 Fig.
Keywords: selective laser melting (SLM), additive manufacturing, powder metallurgy, control of focal spot size, scanning strategy, metals of aerospace industry.

Received: 30.06.2022
Accepted: 29.12.2022

References

1. Sun, Z., Tan, X., Tor, S., Chua, C. (2018) Simultaneously enhanced strength and ductility for 3D-printed stainless steel 316L by selective laser melting. NPG Asia Materials, 10(4), 127-136. https://doi.org/10.1038/s41427-018-0018-5
2. Wang, Y., Voisin, T., McKeown, J. et al. (2017) Additively manufactured hierarchical stainless steels with high strength and ductility. Nature Materials, 17(1), 63-71. https://doi.org/10.1038/nmat5021
3. Yang, W., Tarng, Y. (1998) Design optimization of cutting parameters for turning operations based on the Taguchi method. Journal of Materials Processing Technology, 84(1-3), 122-129. https://doi.org/10.1016/S0924-0136(98)00079-X
4. Mukherjee, T., Manvatkar, V., De, A., DebRoy, T. (2017) Dimensionless numbers in additive manufacturing. Journal of Applied Physics, 121(6), id.064904. https://doi.org/10.1063/1.4976006
5. Ion, J., Shercliff, H., Ashby, M. (1992) Diagrams for laser materials processing. Acta Metallurgica et Materialia, 40(7), 1539-1551. https://doi.org/10.1016/0956-7151(92)90097-X
6. Thomas, M., Baxter, G., Todd, I. (2016) Normalised model-based processing diagrams for additive layer manufacture of engineering alloys. Acta Materialia, 108, 26-35. https://doi.org/10.1016/j.actamat.2016.02.025
7. Jiang, H., Li, Z., Feng, T. et al. (2019) Factor analysis of selective laser melting process parameters with normalised quantities and Taguchi method. Optics & Laser Technology, 119, id.105592. https://doi.org/10.1016/j.optlastec.2019.105592
8. Darvish, K., Chen, Z., Pasang, T. (2016) Reducing lack of fusion during selective laser melting of CoCrMo alloy: Effect of laser power on geometrical features of tracks. Materials & Design, 112, 357-366. https://doi.org/10.1016/j.matdes.2016.09.086
9. Li, Z., Voisin, T., McKeown, J. et al. (2019) Tensile properties, strain rate sensitivity, and activation volume of additively manufactured 316L stainless steels. International Journal of Plasticity, 120, 395-410. https://doi.org/10.1016/j.ijplas.2019.05.009
10. Hou, H., Simsek, E., Ma, T. et al. (2019) Fatigue-resistant high-performance elastocaloric materials made by additive manufacturing. Science, 366(6469), 1116-1121. https://doi.org/10.1126/science.aax7616
11. Ma, M., Wang, Z., Zeng, X. (2017) A comparison on metallurgical behaviors of 316L stainless steel by selective laser melting and laser cladding deposition. Materials Science and Engineering: A, 685, 265-273. https://doi.org/10.1016/j.msea.2016.12.112
12. Jiang, H., Li, Z., Feng, T. et al. (2020) Effect of Process Parameters on Defects, Melt Pool Shape, Microstructure, and Tensile Behavior of 316L Stainless Steel Produced by Selective Laser Melting. Acta Metallurgica Sinica (English Letters), 34(4), 495-510. https://doi.org/10.1007/s40195-020-01143-8
13. Kurzynowski, T., Gruber, K., Stopyra, W. et al. (2018) Correlation between process parameters, microstructure and properties of 316 L stainless steel processed by selective laser melting. Materials Science and Engineering: A, 718, 64-73. https://doi.org/10.1016/j.msea.2018.01.103
14. Martin, A., Calta, N., Khairallah, S. et al. (2019) Dynamics of pore formation during laser powder bed fusion additive manufacturing. Nature Communications, 10(1). https://doi.org/10.1038/s41467-019-10009-2
15. Tang, C., Tan, J., Wong, C. (2018) A numerical investigation on the physical mechanisms of single-track defects in selective laser melting. International Journal of Heat and Mass Transfer, 126, 957-968. https://doi.org/10.1016/j.ijheatmasstransfer.2018.06.073
16. Zheng, M., Wei, L., Chen, J. et al. (2021) On the role of energy input in the surface morphology and microstructure during selective laser melting of Inconel 718 alloy. Journal of Materials Research and Technology, 11, 392-403. https://doi.org/10.1016/j.jmrt.2021.01.024
17. Zheng, M., Wei, L., Chen, J. et al. (2019) A novel method for the molten pool and porosity formation modelling in selective laser melting. International Journal of Heat and Mass Transfer, 140, 1091-1105. https://doi.org/10.1016/j.ijheatmasstransfer.2019.06.038
18. Zheng, M., Wei, L., Chen, J. et al. (2019) Surface morphology evolution during pulsed selective laser melting: Numerical and experimental investigations. Applied Surface Science, 496, id.143649. https://doi.org/10.1016/j.apsusc.2019.143649
19. Deng, C., Kang, J., Feng, T. et al. (2018) Study on the Selective Laser Melting of CuSn10 Powder. Materials, 11(4), 614. https://doi.org/10.3390/ma11040614
20. Kempen, K. (2015) Expanding the materials palette for Selective Laser Melting of metals (Ph.D.). KU Leuven University, Belgium.
21. Wang, L., Wei, Q., Shi, Y. et al. (2011) Experimental Investigation into the Single-Track of Selective Laser Melting of IN625. Advanced Materials Research, 233-235, 2844-2848. https://doi.org/10.4028/www.scientific.net/AMR.233-235.2844
22. Yadroitsev, I., Yadroitsava, I., Bertrand, P., Smurov, I. (2012) Factor analysis of selective laser melting process parameters and geometrical characteristics of synthesized single tracks. Rapid Prototyping Journal, 18(3), 201-208. https://doi.org/10.1108/13552541211218117
23. Promoppatum, P., Yao, S., Pistorius, P., Rollett, A. (2017) A Comprehensive Comparison of the Analytical and Numerical Prediction of the Thermal History and Solidification Microstructure of Inconel 718 Products Made by Laser Powder-Bed Fusion. Engineering, 3(5), 685-694. https://doi.org/10.1016/J.ENG.2017.05.023
24. Brandt, M. (2016) Laser Additive Manufacturing: Materials, Design, Technologies, and Applications. Duxford: Woodhead Publishing, 259-279.
25. Metelkova, J., Kinds, Y., Kempen, K. et al. (2018) On the influence of laser defocusing in Selective Laser Melting of 316L. Additive Manufacturing, 23, 161-169. https://doi.org/10.1016/j.addma.2018.08.006
26. Paraschiv, A., Matache, G., Condruz, M. et al. (2021) The Influence of Laser Defocusing in Selective Laser Melted IN 625. Materials, 14(13), 34-47. https://doi.org/10.3390/ma14133447
27. Zhou, C., Hu, S., Shi, Q. et al. (2020) Improvement of corrosion resistance of SS316L manufactured by selective laser melting through subcritical annealing. Corrosion Science, 164, id.108353. https://doi.org/10.1016/j.corsci.2019.108353
28. McLouth, T., Bean, G., Witkin, D. et al. (2018) The effect of laser focus shift on microstructural variation of Inconel 718 produced by selective laser melting. Materials & Design, 149, 205-213. https://doi.org/10.1016/j.matdes.2018.04.019
29. Laleh, M., Hughes, A., Xu, W. et al. (2020) Unanticipated drastic decline in pitting corrosion resistance of additively manufactured 316L stainless steel after high-temperature post-processing. Corrosion Science, 165, id.108412. https://doi.org/10.1016/j.corsci.2019.108412
30. Duan, Z., Man, C., Dong, C. et al. (2020) Pitting behavior of SLM 316L stainless steel exposed to chloride environments with different aggressiveness: Pitting mechanism induced by gas pores. Corrosion Science, 167, id.108520. https://doi.org/10.1016/j.corsci.2020.108520
31. Kong, D., Ni, X., Dong, C. et al. (2018) Heat treatment effect on the microstructure and corrosion behavior of 316L stainless steel fabricated by selective laser melting for proton exchange membrane fuel cells. Electrochimica Acta, 276, 293-303. https://doi.org/10.1016/j.electacta.2018.04.188
32. Trelewicz, J., Halada, G., Donaldson, O., Manogharan, G. (2016) Microstructure and Corrosion Resistance of Laser Additively Manufactured 316L Stainless Steel. JOM, 68(3), 850-859. https://doi.org/10.1007/s11837-016-1822-4
33. AlMangour, B., Grzesiak, D., Yang, J. (2017) Scanning strategies for texture and anisotropy tailoring during selective laser melting of TiC/316L stainless steel nanocomposites. Journal of Alloys and Compounds, 728, 424-435. https://doi.org/10.1016/j.jallcom.2017.08.022
34. Zhao, C., Bai, Y., Zhang, Y. et al. (2021) Influence of scanning strategy and building direction on microstructure and corrosion behaviour of selective laser melted 316L stainless steel. Materials & Design, 209, id.109999. https://doi.org/10.1016/j.matdes.2021.109999
35. Wang, X., Kang, J., Wang, T. et al. (2019) Effect of Layer-Wise Varying Parameters on the Microstructure and Soundness of Selective Laser Melted INCONEL 718 Alloy. Materials, 12(13), id.2165. https://doi.org/10.3390/ma12132165
36. Strößner, J., Terock, M., Glatzel, U. (2015) Mechanical and Microstructural Investigation of Nickel-Based Superalloy IN718 Manufactured by Selective Laser Melting (SLM). Advanced Engineering Materials, 17(8), 1099-1105. https://doi.org/10.1002/adem.201500158
37. Yi, J., Kang, J., Wang, T. et al. (2021) Microstructure and mechanical behavior of bright crescent areas in Inconel 718 sample fabricated by selective laser melting. Materials & Design, 197, id.109259. https://doi.org/10.1016/j.matdes.2020.109259
38. Wan, H., Zhou, Z., Li, C. et al. (2018) Effect of scanning strategy on grain structure and crystallographic texture of Inconel 718 processed by selective laser melting. Journal of Materials Science & Technology, 34(10), 1799-1804. https://doi.org/10.1016/j.jmst.2018.02.002
39. Popovich, V., Borisov, E., Popovich, A. et al. (2017) Functionally graded Inconel 718 processed by additive manufacturing: Crystallographic texture, anisotropy of microstructure and mechanical properties. Materials & Design, 114, 441-449. https://doi.org/10.1016/j.matdes.2016.10.075
40. Amato, K., Gaytan, S., Murr, L. et al. (2012) Microstructures and mechanical behavior of Inconel 718 fabricated by selective laser melting. Acta Materialia, 60(5), 2229-2239. https://doi.org/10.1016/j.actamat.2011.12.032
41. Liu, X., Wang, K., Hu, P. (2021) Formability, Microstructure and Properties of Inconel 718 Superalloy Fabricated by Selective Laser Melting Additive Manufacture Technology. Materials, 14(4), 991. https://doi.org/10.3390/ma14040991
42. Ji, H., Gupta, M., Song, Q. et al. (2021) Microstructure and machinability evaluation in micro milling of selective laser melted Inconel 718 alloy. Journal of Materials Research and Technology, 14, 348-362. https://doi.org/10.1016/j.jmrt.2021.06.081
43. Sander, G., Thomas, S., Cruz, V. et al. (2017) On The Corrosion and Metastable Pitting Characteristics of 316L Stainless Steel Produced by Selective Laser Melting. Journal of The Electrochemical Society, 164(6), 250-257. https://doi.org/10.1149/2.0551706jes
44. Chao, Q., Cruz, V., Thomas, S. et al. (2017) On the enhanced corrosion resistance of a selective laser melted austenitic stainless steel. Scripta Materialia, 141, 94-98. https://doi.org/10.1016/j.scriptamat.2017.07.037
45. Zhang, Y., Liu, F., Chen, J., Yuan, Y. (2017) Effects of surface quality on corrosion resistance of 316L stainless steel parts manufactured via SLM. Journal of Laser Applications, 29(2), 022306. https://doi.org/10.2351/1.4983263
46. Vignal, V., Voltz, C., Thiébaut, S. et al. (2021) Pitting Corrosion of Type 316L Stainless Steel Elaborated by the Selective Laser Melting Method: Influence of Microstructure. Journal of Materials Engineering and Performance, 30(7), 5050-5058. https://doi.org/10.1007/s11665-021-05621-7

Suggested Citation

M.V. Sokolovskyi (2022) Problems and prospects of studying the processes of selective laser melting of materials for aerospace engineering (Review). The Paton Welding J., 11, 8-16.