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Wire and arc additive manufacturing (WAAM) technology was used for the fabrication of NiTiTa (2.5 at. % Ta) shape memory alloys (SMAs) for the first time, using commercialy available NiTi wire and Ta foil as the feedstock materials. The addition of Ta significantly increased the phase transformation temperatures, leading to a room-temperature microstructure composed of both B19′ martensite and B2 austenite, and (Ti,Ta)2Ni precipitates distributed at the grain boundaries. Compared with the WAAM fabricated NiTi counterpart, the corrosion potential (Ecorr) of the NiTiTa material increased from − 0.55 to − 0.44 V, while the corrosion current density (Icorr) decreased from 1.90 × 10−6 to 4.2 × 10−7 A/cm2. The X-ray brightness increased from 19.6 to 56.4 %. These results indicate that the addition of Ta can enhance the corrosion resistance and X-ray visibility of NiTiTa parts. Furthermore, the WAAM fabricated NiTiTa material was able to retain a stable superelastic response under 10 loading-unloading cycles, highlighting the great potential application value in the biomedical field. Our work provides an innovative method for additively manufacturing NiTi-based multi-component SMAs through WAAM.

17–4 PH (precipitation hardening) stainless steel is commonly used for the fabrication of complicated molds with conformal cooling channels using laser powder bed fusion process (L-PBF). However, their microstructure in the as-printed condition varies notably with the chemical composition of the feedstock powder, resulting in different age-hardening behavior. In the present investigation, 17–4 PH stainless steel components were fabricated by L-PBF from two different feedstock powders, and subsequently subjected to different combinations of post-process heat treatments. It was observed that the microstructure in as-printed conditions could be almost fully martensitic or ferritic, depending on the ratio of Creq/Nieq of the feedstock powder. Aging treatment at 480 °C improved the yield and ultimate tensile strengths of the as-printed components. However, specimens with martensitic structures exhibited accelerated age-hardening response compared with the ferritic specimens due to the higher lattice distortion and dislocation accumulation, resulting in the “dislocation pipe diffusion mechanism”. It was also found that the martensitic structures were highly susceptible to the formation of reverted austenite during direct aging treatment, where 19.5% of austenite phase appeared in the microstructure after 15 h of direct aging. Higher fractions of reverted austenite activates the transformation induced plasticity and improves the ductility of heat treated specimens. The results of the present study can be used to tailor the microstructure of the L-PBF printed 17–4 PH stainless steel by post-process heat treatments to achieve a good combination of mechanical properties.

The fabrication of horizontal interior circular channels poses some unique challenges to the laser powder bed fusion (L-PBF) process. The engineering challenge is to be able to print horizontal interior channels using L-PBF without using support structures, while the scientific challenge is to predict the shape deviation in the horizontal channel. This paper studies the geometric fidelity (roundness and shape deviation) of L-PBF printed horizontal interior circular channels (diameters 1−3 mm) by developing experiment-based regression models and a preliminary computational fluid dynamics (CFD) simulation model. The roundness error is found to be affected by the shape/size of the melt pool, thermal stresses, beam offset, and the slicing algorithm. It is recommended that to decrease the roundness error, in addition to choosing a proper beam offset, the width/depth of the melt pool should be minimized by minimizing the volumetric energy density (smaller laser power or higher scanning speed). Shape deviation in overhanging structures is determined by the thermo-mechanical driven molten flow in the melt pool. Hanging structures with irregular profiles (dross) are formed due to the sinking of the melt pool on an unconsolidated powder bed under the effect of gravity, surface tension, and poor thermal conductivity. (Partially) unmelted powder randomly adheres to the edges of the melt pool enlarging the hanging structure and roughening the profile. Small laser power or large scanning speed benefits reducing the roundness error and hang-diameter ratio. 0° or 45° rotational linear scanning strategy can be selected for minimizing the roundness error or the hang-diameter ratio, respectively.

Powder bed fusion (PBF) is ideally suited to build complex and near-net-shaped metallic structures such as conformal cooling channel networks in injection molds. However, warpage occurring due to the residual stresses inherent to this process can lead to shape deviation in the internal channels and needs to be minimized. In this research, a novel analytical model based on the Euler-Bernoulli beam bending theory was developed to estimate the residual stress-induced deformation of internal channels printed horizontally using PBF. The model was used to predict the shape deviation for three different shapes of channel cross sections (circular, elliptical, and diamond-shaped), and showed very good agreement with the experimentally determined shapes of nine different internal channels (three cases per cross-sectional shape). Further, the model predictions were used to compensate for the shape deviation in the design stage, resulting in a reduction in root mean square (RMS) deviation of the circular channel by a factor of 2. The proposed approach is thus expected to be a useful tool to generate design-for-AM guidelines for the additive manufacturing of overhangs and internal channels.