Chinese Journal of Lasers, Volume. 49, Issue 14, 1402801(2022)
Internal Defects and Control Methods of Laser Powder Bed Fusion Forming
[2] Kranz J, Herzog D, Emmelmann C. Design guidelines for laser additive manufacturing of lightweight structures in TiAl6V4[J]. Journal of Laser Applications, 27, S14001(2015).
[3] Zhang M K, Yang Y Q, Song C H et al. An investigation into the aging behavior of CoCrMo alloys fabricated by selective laser melting[J]. Journal of Alloys and Compounds, 750, 878-886(2018).
[4] Awad A, Fina F, Goyanes A et al. Advances in powder bed fusion 3D printing in drug delivery and healthcare[J]. Advanced Drug Delivery Reviews, 174, 406-424(2021).
[5] Shen X F, Cheng Z Y, Wang C G et al. Effect of heat treatments on the microstructure and mechanical properties of Al-Mg-Sc-Zr alloy fabricated by selective laser melting[J]. Optics & Laser Technology, 143, 107312(2021).
[6] Gu D D, Hagedorn Y C, Meiners W et al. Densification behavior, microstructure evolution, and wear performance of selective laser melting processed commercially pure titanium[J]. Acta Materialia, 60, 3849-3860(2012).
[7] Xu S, Jiang W, Zhou Y N et al. Comprehensive evaluation of the effect of dental unit on the dimensional accuracy of CoCr multi-unit fixed bridge[J]. Materials Express, 10, 2063-2069(2020).
[8] Nicoletto G. Smooth and notch fatigue behavior of selectively laser melted Inconel 718 with as-built surfaces[J]. International Journal of Fatigue, 128, 105211(2019).
[9] Waqar S, Guo K, Sun J. FEM analysis of thermal and residual stress profile in selective laser melting of 316L stainless steel[J]. Journal of Manufacturing Processes, 66, 81-100(2021).
[10] de Jesus J, Martins Ferreira J A, Borrego L et al. Fatigue failure from inner surfaces of additive manufactured Ti–6Al–4V components[J]. Materials, 14, 737(2021).
[11] Bai Y C, Zhao C L, Wang D et al. Evolution mechanism of surface morphology and internal hole defect of 18Ni300 maraging steel fabricated by selective laser melting[J]. Journal of Materials Processing Technology, 299, 117328(2022).
[12] Mumtaz K A, Hopkinson N. Selective Laser Melting of thin wall parts using pulse shaping[J]. Journal of Materials Processing Technology, 210, 279-287(2010).
[13] Koutiri I, Pessard E, Peyre P et al. Influence of SLM process parameters on the surface finish, porosity rate and fatigue behavior of as-built Inconel 625 parts[J]. Journal of Materials Processing Technology, 255, 536-546(2018).
[14] Zhou X, Liu X H, Zhang D D et al. Balling phenomena in selective laser melted tungsten[J]. Journal of Materials Processing Technology, 222, 33-42(2015).
[15] Liu Y, Yang Y Q, Wang D. Investigation into the shrinkage in Z-direction of components manufactured by selective laser melting (SLM)[J]. The International Journal of Advanced Manufacturing Technology, 90, 2913-2923(2017).
[16] Wang D, Ye G Z, Dou W H et al. Influence of spatter particles contamination on densification behavior and tensile properties of CoCrW manufactured by selective laser melting[J]. Optics & Laser Technology, 121, 105678(2020).
[17] Wang D, Dou W H, Ou Y H et al. Characteristics of droplet spatter behavior and process-correlated mapping model in laser powder bed fusion[J]. Journal of Materials Research and Technology, 12, 1051-1064(2021).
[19] Wang D, Deng G W, Yang Y Q et al. Interface microstructure and mechanical properties of selective laser melted multilayer functionally graded materials[J]. Journal of Central South University, 28, 1155-1169(2021).
[20] Buchbinder D, Meiners W, Pirch N et al. Investigation on reducing distortion by preheating during manufacture of aluminum components using selective laser melting[J]. Journal of Laser Applications, 26, 012004(2014).
[21] Kim W R, Bang G B, Park J H et al. Microstructural study on a Fe-10Cu alloy fabricated by selective laser melting for defect-free process optimization based on the energy density[J]. Journal of Materials Research and Technology, 9, 12834-12839(2020).
[22] Lü F, Liang H X, Xie D Q et al. On the role of laser in situ re-melting into pore elimination of Ti–6Al–4V components fabricated by selective laser melting[J]. Journal of Alloys and Compounds, 854, 156866(2021).
[23] Seede R, Ye J H, Whitt A et al. Effect of composition and phase diagram features on printability and microstructure in laser powder bed fusion: development and comparison of processing maps across alloy systems[J]. Additive Manufacturing, 47, 102258(2021).
[24] Kruth J P, Froyen L, Vaerenbergh J V et al. Selective laser melting of iron-based powder[J]. Journal of Materials Processing Technology, 149, 616-622(2004).
[25] Wu W H, Yang Y Q, Wang D. Balling phenomenon in selective laser melting process[J]. Journal of South China University of Technology (Natural Science Edition), 38, 110-115(2010).
[26] Bai Y C[D]. Research on the mechanism and properties controllability of selective laser melting of maraging steel(2018).
[27] Mutua J, Nakata S, Onda T et al. Optimization of selective laser melting parameters and influence of post heat treatment on microstructure and mechanical properties of maraging steel[J]. Materials & Design, 139, 486-497(2018).
[28] Jia Q B, Gu D D. Selective laser melting additive manufacturing of Inconel 718 superalloy parts: densification, microstructure and properties[J]. Journal of Alloys and Compounds, 585, 713-721(2014).
[29] Wu W H, Yang Y Q. Optimization of molten metal line morphology in selective laser melting[J]. Foundry Technology, 33, 1308-1311(2012).
[30] Aboulkhair N T, Maskery I, Tuck C et al. On the formation of AlSi10Mg single tracks and layers in selective laser melting: microstructure and nano-mechanical properties[J]. Journal of Materials Processing Technology, 230, 88-98(2016).
[31] Attar H, Calin M, Zhang L C et al. Manufacture by selective laser melting and mechanical behavior of commercially pure titanium[J]. Materials Science and Engineering: A, 593, 170-177(2014).
[32] Wang D, Wu S B, Fu F et al. Mechanisms and characteristics of spatter generation in SLM processing and its effect on the properties[J]. Materials & Design, 117, 121-130(2017).
[33] Ye D S, Zhu K P, Fuh J Y H et al. The investigation of plume and spatter signatures on melted states in selective laser melting[J]. Optics & Laser Technology, 111, 395-406(2019).
[34] Liu Y D, Zhang M, Shi W T et al. Study on performance optimization of 316L stainless steel parts by high-efficiency selective laser melting[J]. Optics & Laser Technology, 138, 106872(2021).
[35] Lu C, Xiao M Z, Qu Y B et al. Evolution mechanism of powder properties of recycled 316L stainless steel in selective laser melting[J]. Chinese Journal of Lasers, 48, 1402009(2021).
[36] Liu Y, Yang Y Q, Mai S Z et al. Investigation into spatter behavior during selective laser melting of AISI 316L stainless steel powder[J]. Materials & Design, 87, 797-806(2015).
[37] Liu Y[D]. Research on the mechanism of selective laser melting and direct manufacturing of structural features(2015).
[38] Zhang B, Li Y T, Bai Q. Defect formation mechanisms in selective laser melting: a review[J]. Chinese Journal of Mechanical Engineering, 30, 515-527(2017).
[39] Wang D, Qian Z Y, Dou W H et al. Research progress on selective laser melting of nickel based superalloy[J]. Aeronautical Manufacturing Technology, 61(2018).
[40] Scipioni Bertoli U, Wolfer A J, Matthews M J et al. On the limitations of volumetric energy density as a design parameter for selective laser melting[J]. Materials & Design, 113, 331-340(2017).
[41] Tan P F, Kiran R, Zhou K. Effects of sub-atmospheric pressure on keyhole dynamics and porosity in products fabricated by selective laser melting[J]. Journal of Manufacturing Processes, 64, 816-827(2021).
[42] Hojjatzadeh S M H, Parab N D, Yan W et al. Pore elimination mechanisms during 3D printing of metals[J]. Nature Communications, 10, 3088(2019).
[43] Zhao C, Parab N D, Li X X et al. Critical instability at moving keyhole tip generates porosity in laser melting[J]. Science, 370, 1080-1086(2020).
[44] Li C, Mi G B, Feng A H et al. Research progress in defect and microstructure of as-built selective laser melting Ti–6Al–4V titanium alloy[J]. Aeronautical Manufacturing Technology, 64, 44-51(2021).
[45] Zhang S, Gui R Z, Wei Q S et al. Cracking behavior and formation mechanism of TC4 alloy formed by selective laser melting[J]. Journal of Mechanical Engineering, 49, 21-27(2013).
[46] Sames W J, List F A, Pannala S et al. The metallurgy and processing science of metal additive manufacturing[J]. International Materials Reviews, 61, 315-360(2016).
[47] Tan Q Y, Liu Y G, Fan Z Q et al. Effect of processing parameters on the densification of an additively manufactured 2024 Al alloy[J]. Journal of Materials Science & Technology, 58, 34-45(2020).
[48] Martin J H, Yahata B D, Hundley J M et al. 3D printing of high-strength aluminium alloys[J]. Nature, 549, 365-369(2017).
[49] Nie X J, Zhang H, Zhu H H et al. Effect of Zr content on formability, microstructure and mechanical properties of selective laser melted Zr modified Al-4.24Cu-1.97Mg-0.56Mn alloys[J]. Journal of Alloys and Compounds, 764, 977-986(2018).
[50] Chen J, Yang Y Q, Wang D et al. Effect of manufacturing steps on the interfacial defects of laser powder bed fusion 316L/CuSn10[J]. Materials Letters, 292, 129377(2021).
[51] Liu L Q, Song C H, Yang Y Q et al. Study on mechanism of strengthening interface structure of dissimilar materials by selective laser melting[J]. Journal of Mechanical Engineering, 56, 189-196(2020).
[52] Harrison N J, Todd I, Mumtaz K. Reduction of micro-cracking in nickel superalloys processed by Selective Laser Melting: a fundamental alloy design approach[J]. Acta Materialia, 94, 59-68(2015).
[53] Mugwagwa L, Dimitrov D, Matope S et al. Influence of process parameters on residual stress related distortions in selective laser melting[J]. Procedia Manufacturing, 21, 92-99(2018).
[54] Liu Y, Yang Y Q, Wang D. A study on the residual stress during selective laser melting (SLM) of metallic powder[J]. The International Journal of Advanced Manufacturing Technology, 87, 647-656(2016).
[55] Zhang G Q, Yang Y Q, Zhang Z M et al. Optimal design of support structures in selective laser melting of parts[J]. Chinese Journal of Lasers, 43, 1202002(2016).
[56] Li R D, Liu J H, Shi Y S et al. Balling behavior of stainless steel and nickel powder during selective laser melting process[J]. The International Journal of Advanced Manufacturing Technology, 59, 1025-1035(2012).
[57] Zhou X, Wang D Z, Liu X H et al. 3D-imaging of selective laser melting defects in a Co-Cr-Mo alloy by synchrotron radiation micro-CT[J]. Acta Materialia, 98, 1-16(2015).
[58] Sato Y, Srisawadi S, Tanprayoon D et al. Spatter behavior for 316L stainless steel fabricated by selective laser melting in a vacuum[J]. Optics and Lasers in Engineering, 134, 106209(2020).
[59] Jing G Y, Wang Z M. Defects, densification mechanism and mechanical properties of 300M steel deposited by high power selective laser melting[J]. Additive Manufacturing, 38, 101831(2021).
[60] Ma W, Ning J, Zhang L J et al. Regulation of microstructures and properties of molybdenum-silicon-boron alloy subjected to selective laser melting[J]. Journal of Manufacturing Processes, 69, 593-601(2021).
[61] Deng G W, Tan C L, Wang D et al. Defects suppression and mechanism in additive manufacturing high-volume SiC reinforced maraging steel[J]. Journal of Mechanical Engineering, 57, 243-252(2021).
[62] Narvan M, Al-Rubaie K S, Elbestawi M. Process-structure-property relationships of AISI H13 tool steel processed with selective laser melting[J]. Materials, 12, 2284(2019).
[63] Tan Q Y, Fan Z Q, Tang X Q et al. A novel strategy to additively manufacture 7075 aluminium alloy with selective laser melting[J]. Materials Science and Engineering: A, 821, 141638(2021).
[64] McLouth T D, Bean G E, Witkin D B et al. The effect of laser focus shift on microstructural variation of Inconel 718 produced by selective laser melting[J]. Materials & Design, 149, 205-213(2018).
[65] Zhang L L, Wang M J, Zhang J Q et al. Effect of defocus distance on formability of CX maraging stainless steel by selective laser melting[J]. Chinese Journal of Lasers, 48, 2202020(2021).
[66] Zhang J Q, Wang M J, Liu J Y et al. Influence of defocusing distance on microstructure and mechanical properties of 3D-printed 18Ni-300 maraging steel[J]. Chinese Journal of Lasers, 47, 0502004(2020).
[67] Tumkur T U, Voisin T, Shi R P et al. Nondiffractive beam shaping for enhanced optothermal control in metal additive manufacturing[J]. Science Advances, 7, eabg9358(2021).
[68] Roehling T T, Wu S S Q, Khairallah S A et al. Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing[J]. Acta Materialia, 128, 197-206(2017).
[69] Matthews M J, Roehling T T, Khairallah S A et al. Spatial modulation of laser sources for microstructural control of additively manufactured metals[J]. Procedia CIRP, 74, 607-610(2018).
[70] Xia L Q, Chen G, Zheng L Y et al. Explore the feasibility of fabricating pure copper parts with low-laser energy by selective laser melting[J]. Materials Research Express, 7, 106509(2020).
[71] Hori E, Sato Y, Shibata T et al. Development of SLM process using 200 W blue diode laser for pure copper additive manufacturing of high density structure[J]. Journal of Laser Applications, 33, 012008(2021).
[72] Chen J, Liao X Y, Shu J G et al. Microstructure tailoring of Ti-15Mo alloy fabricated by selective laser melting with high strength and ductility[J]. Materials Science and Engineering: A, 826, 141962(2021).
[73] Guraya T, Singamneni S, Chen Z W. Microstructure formed during selective laser melting of IN738LC in keyhole mode[J]. Journal of Alloys and Compounds, 792, 151-160(2019).
[74] Chen J, Yang Y Q, Song C H et al. Influence mechanism of process parameters on the interfacial characterization of selective laser melting 316L/CuSn10[J]. Materials Science and Engineering: A, 792, 139316(2020).
[75] Dou W H[D]. Research on the spatter behavior in laser powder bed fusion process(2020).
[76] Aboulkhair N T, Everitt N M, Ashcroft I et al. Reducing porosity in AlSi10Mg parts processed by selective laser melting[J]. Additive Manufacturing, 1/2/3/4, 77-86(2014).
[77] Zhang S L, Wang J H, Li X F et al. Main defects and control methods of aluminum alloys fabricated by selective laser melting[J]. Materials China, 40, 267-274(2021).
[78] Yan T Q, Chen B Q, Tang P J et al. Effect of layer thickness on forming quality and efficiency of AlSi10Mg alloy fabricated by selective laser melting[J]. Chinese Journal of Lasers, 48, 1002106(2021).
[79] Mugwagwa L, Dimitrov D, Matope S et al. Evaluation of the impact of scanning strategies on residual stresses in selective laser melting[J]. The International Journal of Advanced Manufacturing Technology, 102, 2441-2450(2019).
[80] Deng S S, Yang Y Q, Li Y et al. Planning of area-partition scanning path and its effect on residual stress of SLM molding parts[J]. Chinese Journal of Lasers, 43, 1202003(2016).
[81] Cao L. Mesoscopic-scale numerical investigation including the influence of scanning strategy on selective laser melting process[J]. Computational Materials Science, 189, 110263(2021).
[82] Yu W H, Sing S L, Chua C K et al. Influence of re-melting on surface roughness and porosity of AlSi10Mg parts fabricated by selective laser melting[J]. Journal of Alloys and Compounds, 792, 574-581(2019).
[83] Lauwers B, Klocke F, Klink A et al. Hybrid processes in manufacturing[J]. CIRP Annals, 63, 561-583(2014).
[84] Yang Z F, Zhang Y K. Research and development of hybrid additive manufacturing technology[J]. Electromachining & Mould, 1-7(2019).
[85] Du W, Bai Q, Zhang B. A novel method for additive/subtractive hybrid manufacturing of metallic parts[J]. Procedia Manufacturing, 5, 1018-1030(2016).
[86] Bai Q, Wu B Z, Qiu X L et al. Experimental study on additive/subtractive hybrid manufacturing of 6511 steel: process optimization and machining characteristics[J]. The International Journal of Advanced Manufacturing Technology, 108, 1389-1398(2020).
[87] Zhang Y J, Song B, Zhao X et al. Selective laser melting and subtractive hybrid manufacture AISI420 stainless steel: evolution on surface roughness and residual stress[J]. Journal of Mechanical Engineering, 54, 170-178(2018).
[88] Furumoto T, Abe S, Yamaguchi M et al. Improving surface quality using laser scanning and machining strategy combining powder bed fusion and machining processes[J]. The International Journal of Advanced Manufacturing Technology, 117, 3405-3413(2021).
[89] Kang N, Coddet P, Wang J et al. A novel approach to in situ produce functionally graded silicon matrix composite materials by selective laser melting[J]. Composite Structures, 172, 251-258(2017).
[90] Du D F, Haley J C, Dong A P et al. Influence of static magnetic field on microstructure and mechanical behavior of selective laser melted AlSi10Mg alloy[J]. Materials & Design, 181, 107923(2019).
[91] Zhu W L, Yu S, Chen C Y et al. Effects of static magnetic field on the microstructure of selective laser melted Inconel 625 superalloy: numerical and experiment investigations[J]. Metals, 11, 1846(2021).
[92] Shuai S S, Lin X, Xiao W Q et al. Effect of transverse static magnetic field on microstructure of Al-12%Si alloys fabricated by powder-blow additive manufacturing[J]. Acta Metallurgica Sinica, 54, 918-926(2018).
[93] Hu Y, Wang L, Lou F X et al. Mechanism study of steady magnetic field effect on spherical WC particle distribution during laser melt injection[J]. Journal of Mechanical Engineering, 57, 240-248(2021).
[95] Zhang M X, Liu C M, Shi X Z et al. Residual stress, defects and grain morphology of Ti-6Al-4V alloy produced by ultrasonic impact treatment assisted selective laser melting[J]. Applied Sciences, 6, 304(2016).
[96] Tilita G A, Chen W H, Leung C K L et al. Influence of ultrasonic excitation on the mechanical characteristics of SLM 304L stainless steel[J]. Procedia Engineering, 216, 18-27(2017).
[97] Hu Y B, Ning F D, Cong W L et al. Ultrasonic vibration-assisted laser engineering net shaping of ZrO2-Al2O3 bulk parts: effects on crack suppression, microstructure, and mechanical properties[J]. Ceramics International, 44, 2752-2760(2018).
[98] Wang H, Hu Y B, Ning F D et al. Ultrasonic vibration-assisted laser engineered net shaping of Inconel 718 parts: effects of ultrasonic frequency on microstructural and mechanical properties[J]. Journal of Materials Processing Technology, 276, 116395(2020).
[99] Qin L Y, Wang W, Yang G. Experimental study on ultrasonic-assisted laser metal deposition of titanium alloy[J]. Chinese Journal of Lasers, 40, 0103001(2013).
[100] Cen W H, Tang H L, Zhang J Z et al. Scanning strategy to improve the overlapping quality of partition in selective laser melting[J]. Chinese Journal of Lasers, 48, 1802018(2021).
[101] Sing S L, Yeong W Y. Laser powder bed fusion for metal additive manufacturing: perspectives on recent developments[J]. Virtual and Physical Prototyping, 15, 359-370(2020).
[102] Wei C, Li L. Recent progress and scientific challenges in multi-material additive manufacturing via laser-based powder bed fusion[J]. Virtual and Physical Prototyping, 16, 347-371(2021).
[103] Zhang J L, Song B, Wei Q S et al. A review of selective laser melting of aluminum alloys: processing, microstructure, property and developing trends[J]. Journal of Materials Science & Technology, 35, 270-284(2019).
[104] Cao L C, Zhou Q, Han Y F et al. Review on intelligent monitoring of defects and process control of selective laser melting additive manufacturing[J]. Acta Aeronautica et Astronautica Sinica, 42, 524790(2021).
Get Citation
Copy Citation Text
Changhui Song, Houxiong Fu, Zhongwei Yan, Yongjie Zeng, Hanxiang Zhou, Yongqiang Yang. Internal Defects and Control Methods of Laser Powder Bed Fusion Forming[J]. Chinese Journal of Lasers, 2022, 49(14): 1402801
Received: Dec. 20, 2021
Accepted: Feb. 24, 2022
Published Online: Jun. 14, 2022
The Author Email: Song Changhui (song_changhui@163.com)