International Journal of Extreme Manufacturing, Volume. 6, Issue 2, 25001(2024)

Printability disparities in heterogeneous material combinations via laser directed energy deposition: a comparative study

Jinsheng Ning1... Lida Zhu1, Shuhao Wang2, Zhichao Yang1, Peihua Xu1, Pengsheng Xue3, Hao Lu1, Miao Yu1, Yunhang Zhao1, Jiachen Li4, Susmita Bose5 and Amit Bandyopadhyay5,* |Show fewer author(s)
Author Affiliations
  • 1School of Mechanical Engineering and Automation, Northeastern University, Shenyang 110819,People’s Republic of China
  • 2School of Machinery and Automation, Wuhan University of Science and Technology, Wuhan 430081,People’s Republic of China
  • 3School of Mechanical Engineering, Xi’an University of Science and Technology, Xi’an 710054,People’s Republic of China
  • 4Beijing Institute of Space Launch Technology, Beijing 100076, People’s Republic of China
  • 5W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering,Washington State University, Pullman, WA 99164, United States of America
  • show less
    References(70)

    [1] [1] Tan C L, Weng F, Sui S, Chew Y and Bi G J 2021 Progress and perspectives in laser additive manufacturing of key aeroengine materials Int. J. Mach. Tools Manuf.170 103804

    [2] [2] Bandyopadhyay A, Traxel K D, Lang M, Juhasz M, Eliaz N and Bose S 2022 Alloy design via additive manufacturing:advantages, challenges, applications and perspectives Mater. Today 52 207–24

    [3] [3] Sui S, Chew Y, Weng F, Tan C L, Du Z L and Bi G J 2022 Study of the intrinsic mechanisms of nickel additive for grain refinement and strength enhancement of laser aided additively manufactured Ti–6Al–4V Int. J. Extrem. Manuf.4 035102

    [4] [4] Xue P S, Zhu L D, Xu P H, Ren Y, Xin B, Meng G R,Yang Z C and Liu Z 2021 Research on process optimization and microstructure of CrCoNi medium-entropy alloy formed by laser metal deposition Opt. Laser Technol.142 107167

    [5] [5] Bandyopadhyay A, Traxel K D and Bose S 2021 Nature-inspired materials and structures using 3D printing Mater. Sci. Eng. R 145 100609

    [6] [6] Zuback J S, Palmer T A and DebRoy T 2019 Additive manufacturing of functionally graded transition joints between ferritic and austenitic alloys J. Alloys Compd.770 995–1003

    [7] [7] Feenstra D R, Banerjee R, Fraser H L, Huang A, Molotnikov A and Birbilis N 2021 Critical review of the state of the art in multi-material fabrication via directed energy deposition Curr. Opin. Solid State Mater. Sci. 25 100924

    [8] [8] Wei C, Zhang Z Z, Cheng D X, Sun Z, Zhu M H and Li L 2021 An overview of laser-based multiple metallic material additive manufacturing: from macro- to micro-scales Int. J.Extrem. Manuf. 3 012003

    [9] [9] Gu D D, Shi X Y, Poprawe R, Bourell D L, Setchi R and Zhu J H 2021 Material-structure-performance integrated laser-metal additive manufacturing Science 372 eabg1487

    [10] [10] Bandyopadhyay A and Heer B 2018 Additive manufacturing of multi-material structures Mater. Sci. Eng. R 129 1–16

    [11] [11] Tammas-Williams S and Todd I 2017 Design for additive manufacturing with site-specific properties in metals and alloys Scr. Mater. 135 105–10

    [12] [12] Chen W, Gu D D, Yang J K, Yang Q, Chen J and Shen X F 2022 Compressive mechanical properties and shape memory effect of NiTi gradient lattice structures fabricated by laser powder bed fusion Int. J. Extrem. Manuf. 4 045002

    [13] [13] Svetlizky D, Das M, Zheng B L, Vyatskikh A L, Bose S,Bandyopadhyay A, Schoenung J M, Lavernia E J and Eliaz N 2021 Directed energy deposition (DED) additive manufacturing: physical characteristics, defects, challenges and applications Mater. Today 49 271–95

    [14] [14] Panwisawas C, Tang Y T and Reed R C 2020 Metal 3D printing as a disruptive technology for superalloys Nat.Commun. 11 2327

    [15] [15] Wang S H, Ning J S, Zhu L D, Yang Z C, Yan W T, Dun Y C,Xue P S, Xu P H, Bose S and Bandyopadhyay A 2022 Role of porosity defects in metal 3D printing: formation mechanisms, impacts on properties and mitigation strategies Mater. Today 59 133–60

    [16] [16] DebRoy T, Mukherjee T, Milewski J O, Elmer J W, Ribic B,Blecher J J and Zhang W 2019 Scientific, technological and economic issues in metal printing and their solutions Nat.Mater. 18 1026–32

    [17] [17] Afrouzian A, Groden C J, Field D P, Bose S and Bandyopadhyay A 2022 Additive manufacturing of Ti-Ni bimetallic structures Mater. Des. 215 110461

    [18] [18] Bandyopadhyay A, Zhang Y N and Onuike B 2022 Additive manufacturing of bimetallic structures Virtual Phys.Prototyp. 17 256–94

    [19] [19] Onuike B, Heer B and Bandyopadhyay A 2018 Additive manufacturing of Inconel 718—copper alloy bimetallic structure using laser engineered net shaping (LENSTM)Addit. Manuf. 21 133–40

    [20] [20] Sahasrabudhe H, Harrison R, Carpenter C and Bandyopadhyay A 2015 Stainless steel to titanium bimetallic structure using LENSTM Addit. Manuf. 5 1–8

    [21] [21] Li B Y, Han C J, Lim C W J and Zhou K 2022 Interface formation and deformation behaviors of an additively manufactured nickel-aluminum-bronze/15-5 PH multimaterial via laser-powder directed energy deposition Mater. Sci. Eng. A 829 142101

    [22] [22] Zhang X C, Pan T, Chen Y T, Li L, Zhang Y L and Liou F 2021 Additive manufacturing of copper-stainless steel hybrid components using laser-aided directed energy deposition J. Mater. Sci. Technol. 80 100–16

    [23] [23] Shinjo J and Panwisawas C 2022 Chemical species mixing during direct energy deposition of bimetallic systems using titanium and dissimilar refractory metals for repair and biomedical applications Addit. Manuf. 51 102654

    [24] [24] Wang D et al 2022 Recent progress on additive manufacturing of multi-material structures with laser powder bed fusion Virtual Phys. Prototyp. 17 329–65

    [25] [25] Lin X, Yue T M, Yang H O and Huang W D 2005 Laser rapid forming of SS316L/Rene88DT graded material Mater. Sci.Eng. A 391 325–36

    [26] [26] Melzer D, Dˇzugan J, Koukolíková M, Rzepa S and Vavˇrík J 2021 Structural integrity and mechanical properties of the functionally graded material based on 316L/IN718 processed by DED technology Mater. Sci. Eng. A811 141038

    [27] [27] Melzer D, Dˇzugan J, Koukolíková M, Rzepa S, Dlouh′y J,Brázda M and Bucki T 2022 Fracture characterisation of vertically build functionally graded 316L stainless steel with Inconel 718 deposited by directed energy deposition process Virtual Phys. Prototyp. 17 821–40

    [28] [28] Zhang Y N and Bandyopadhyay A 2018 Direct fabrication of compositionally graded Ti-Al2O3 multi-material structures using laser engineered net shaping Addit. Manuf. 21 104–11

    [29] [29] Ben-Artzy A, Reichardt A, Borgonia P J, Dillon R P,McEnerney B, Shapiro A A and Hosemann P 2021 Compositionally graded SS316 to C300 maraging steel using additive manufacturing Mater. Des. 201 109500

    [30] [30] Tan C L, Liu Y C, Weng F, Ng F L, Su J L, Xu Z K, Ngai X D and Chew Y 2022 Additive manufacturing of voxelized heterostructured materials with hierarchical phases Addit.Manuf. 54 102775

    [31] [31] Chen J, Yang Y Q, Song C H, Zhang M K, Wu S B and Wang D 2019 Interfacial microstructure and mechanical properties of 316L/CuSn10 multi-material bimetallic structure fabricated by selective laser melting Mater. Sci.Eng. A 752 75–85

    [32] [32] Wei C, Gu H, Gu Y C, Liu L C, Huang Y H, Cheng D X,Li Z Q and Li L 2022 Abnormal interfacial bonding mechanisms of multi-material additive-manufactured tungsten–stainless steel sandwich structure Int. J. Extrem.Manuf. 4 025002

    [33] [33] Zhang Y N and Bandyopadhyay A 2021 Influence of compositionally graded interface on microstructure and compressive deformation of 316L stainless steel to Al12Si aluminum alloy bimetallic structures ACS Appl. Mater.Interfaces 13 9174–85

    [34] [34] Wei C et al 2022 Cu10Sn to Ti6Al4V bonding mechanisms in laser-based powder bed fusion multiple material additive manufacturing with different build strategies Addit. Manuf.51 102588

    [35] [35] Li W, Karnati S, Kriewall C, Liou F, Newkirk J, Brown Taminger K M and Seufzer W J 2017 Fabrication and characterization of a functionally graded material from Ti-6Al-4V to SS316 by laser metal deposition Addit.Manuf. 14 95–104

    [36] [36] Shi Q M, Zhong G Y, Sun Y, Politis C and Yang S F 2021 Effects of laser melting+remelting on interfacial macrosegregation and resulting microstructure and microhardness of laser additive manufactured H13/IN625 bimetals J. Manuf. Process. 71 345–55

    [37] [37] Zhang W X, Hou W Y, Deike L and Arnold C 2022 Understanding the Rayleigh instability in humping phenomenon during laser powder bed fusion process Int. J.Extrem. Manuf. 4 015201

    [38] [38] Chen Y W, Zhang X, Li M M, Xu R Q, Zhao C and Sun T 2020 Laser powder bed fusion of Inconel 718 on 316 stainless steel Addit. Manuf. 36 101500

    [39] [39] Yang Z C, Wang S H, Zhu L D, Ning J S, Xin B, Dun Y C and Yan W T 2022 Manipulating molten pool dynamics during metal 3D printing by ultrasound Appl. Phys. Rev.9 021416

    [40] [40] Hofmann D C, Roberts S, Otis R, Kolodziejska J, Dillon R P,Suh J O, Shapiro A A, Liu Z K and Borgonia J P 2014 Developing gradient metal alloys through radial deposition additive manufacturing Sci. Rep. 4 5357

    [41] [41] Tumkur T U et al 2021 Nondiffractive beam shaping for enhanced optothermal control in metal additive manufacturing Sci. Adv. 7 eabg9358

    [42] [42] Scipioni Bertoli U, Guss G, Wu S, Matthews M J and Schoenung J M 2017 In-situ characterization of laser-powder interaction and cooling rates through high-speed imaging of powder bed fusion additive manufacturing Mater. Des. 135 385–96

    [43] [43] Siva Prasad H, Brueckner F and Kaplan A F H 2020 Powder incorporation and spatter formation in high deposition rate blown powder directed energy deposition Addit. Manuf.35 101413

    [44] [44] Ebrahimi A, Kleijn C R and Richardson I M 2021 Numerical study of molten metal melt pool behaviour during conduction-mode laser spot melting J. Appl. Phys.54 105304

    [45] [45] Mumtaz K A and Hopkinson N 2010 Selective laser melting of thin wall parts using pulse shaping J. Mater. Process. Technol. 210 279–87

    [46] [46] Sikandar Iquebal A, Yadav A, Botcha B, Krishna Gorthi R and Bukkapatnam S 2022 Tracking and quantifying spatter characteristics in a laser directed energy deposition process using Kalman filter Manuf. Lett. 33 692–700

    [47] [47] Criales L E, Ar?soy Y M, Lane B, Moylan S, Donmez A and ?zel T 2017 Laser powder bed fusion of nickel alloy 625:experimental investigations of effects of process parameters on melt pool size and shape with spatter analysis Int. J.Mach. Tools Manuf. 121 22–36

    [48] [48] Coen V, Goossens L and van Hooreweder B 2022 Methodology and experimental validation of analytical melt pool models for laser powder bed fusion J. Mater. Process.Technol. 304 117547

    [49] [49] Zhao C, Shi B, Chen S L, Du D, Sun T, Simonds B J, Fezzaa K and Rollett A D 2022 Laser melting modes in metal powder bed fusion additive manufacturing Rev. Mod. Phys.94 045002

    [50] [50] Wang J H, Han F Z, Chen S F and Ying W S 2019 A novel model of laser energy attenuation by powder particles for laser solid forming Int. J. Mach. Tools Manuf.145 103440

    [51] [51] Haley J C, Schoenung J M and Lavernia E J 2018 Observations of particle-melt pool impact events in directed energy deposition Addit. Manuf. 22 368–74

    [52] [52] Chen Y H et al 2021 Correlative synchrotron x-ray imaging and diffraction of directed energy deposition additive manufacturing Acta Mater. 209 116777

    [53] [53] Khorasani M, Ghasemi A, Leary M, Cordova L, Sharabian E,Farabi E, Gibson I, Brandt M and Rolfe B 2022 A comprehensive study on meltpool depth in laser-based powder bed fusion of Inconel 718 Int. J. Adv. Manuf.Technol. 120 2345–62

    [54] [54] Shamsaei N, Yadollahi A, Bian L and Thompson S M 2015 An overview of direct laser deposition for additive manufacturing; part II: mechanical behavior, process parameter optimization and control Addit. Manuf. 8 12–35

    [55] [55] Ghanavati R, Naffakh-Moosavy H, Moradi M and Eshraghi M 2022 Printability and microstructure of directed energy deposited SS316l-IN718 multi-material: numerical modeling and experimental analysis Sci. Rep. 12 16600

    [56] [56] Galbusera F, Demir A G, Platl J, Turk C, Schnitzer R and Previtali B 2022 Processability and cracking behaviour of novel high-alloyed tool steels processed by laser powder bed fusion J. Mater. Process. Technol. 302 117435

    [57] [57] Wang A et al 2023 Effects of processing parameters on pore defects in blue laser directed energy deposition of aluminum by in and ex situ observation J. Mater. Process.Technol. 319 118068

    [58] [58] Hinojos A, Mireles J, Reichardt A, Frigola P, Hosemann P,Murr L E and Wicker R B 2016 Joining of Inconel 718 and 316 stainless steel using electron beam melting additive manufacturing technology Mater. Des. 94 17–27

    [59] [59] Yang Z C, Zhu L D, Wang S H, Ning J S, Dun Y C,Meng G R, Xue P S, Xu P H and Xin B 2021 Effects of ultrasound on multilayer forming mechanism of Inconel718 in directed energy deposition Addit. Manuf. 48 102462

    [60] [60] Yao L M, Huang S, Ramamurty U and Xiao Z M 2021 On the formation of “Fish-scale” morphology with curved grain interfacial microstructures during selective laser melting of dissimilar alloys Acta Mater. 220 117331

    [61] [61] Ghanavati R, Naffakh-Moosavy H and Moradi M 2021 Additive manufacturing of thin-walled SS316L-IN718 functionally graded materials by direct laser metal deposition J. Mater. Res. Technol. 15 2673–85

    [62] [62] Chen N N, Khan H A, Wan Z X, Lippert J, Sun H, Shang S L,Liu Z K and Li J J 2020 Microstructural characteristics and crack formation in additively manufactured bimetal material of 316L stainless steel and Inconel 625 Addit.Manuf. 32 101037

    [63] [63] Xiao Y H, Wan Z X, Liu P W, Wang Z, Li J J and Chen L 2022 Quantitative simulations of grain nucleation and growth at additively manufactured bimetallic interfaces of SS316L and IN625 J. Mater. Process. Technol. 302 117506

    [64] [64] Mukherjee T, DebRoy T, Lienert T J, Maloy S A and Hosemann P 2021 Spatial and temporal variation of hardness of a printed steel part Acta Mater. 209 116775

    [65] [65] Dinda G P, Dasgupta A K and Mazumder J 2021 Texture control during laser deposition of nickel-based superalloy Scr. Mater. 67 503–6

    [66] [66] Tan Z E, Pang J H L, Kaminski J and Pepin H 2019 Characterisation of porosity, density, and microstructure of directed energy deposited stainless steel AISI 316L Addit. Manuf. 25 286–96

    [67] [67] Wolff S J, Gan Z T, Lin S, Bennett J L, Yan W T, Hyatt G,Ehmann K F, Wagner G J, Liu W K and Cao J 2019 Experimentally validated predictions of thermal history and microhardness in laser-deposited Inconel 718 on carbon steel Addit. Manuf. 27 540–51

    [68] [68] Zhang L, Wen M, Imade M, Fukuyama S and Yokogawa K 2008 Effect of nickel equivalent on hydrogen gas embrittlement of austenitic stainless steels based on type 316 at low temperatures Acta Mater. 56 3414–21

    [69] [69] Zuback J S and DebRoy T 2018 The hardness of additively manufactured alloys Materials 11 2070

    [70] [70] Adomako N K, Lewandowski J J, Arkhurst B M, Choi H,Chang H J and Kim J H 2022 Microstructures and mechanical properties of multi-layered materials composed of Ti-6Al-4V, vanadium, and 17–4PH stainless steel produced by directed energy deposition Addit. Manuf.59 103174

    Tools

    Get Citation

    Copy Citation Text

    Jinsheng Ning, Lida Zhu, Shuhao Wang, Zhichao Yang, Peihua Xu, Pengsheng Xue, Hao Lu, Miao Yu, Yunhang Zhao, Jiachen Li, Susmita Bose, Amit Bandyopadhyay. Printability disparities in heterogeneous material combinations via laser directed energy deposition: a comparative study[J]. International Journal of Extreme Manufacturing, 2024, 6(2): 25001

    Download Citation

    EndNote(RIS)BibTexPlain Text
    Save article for my favorites
    Paper Information

    Received: May. 30, 2023

    Accepted: --

    Published Online: Sep. 6, 2024

    The Author Email: Bandyopadhyay Amit (amitband@wsu.edu)

    DOI:10.1088/2631-7990/ad172f

    Topics