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Laser-based powder bed fusion of metals (PBF-LB/M) is a widely used additive manufacturing process characterized by a high degree of design freedom. As a result, near fully dense complex components can be produced in near-net shape by PBF-LB/M. Recently, the PBF-LB/M process was found to be a promising candidate to overcome challenges related to conventional machining of the Fe64Ni36 Invar alloy being well known for a low coefficient of thermal expansion (CTE). In this context, a correlation between process-induced porosity and the CTE was presumed in several studies. Therefore, the present study investigates whether the unique thermal properties of the PBF-LB/M-processed Fe64Ni36 Invar alloy can be tailored by the selective integration of defects. For this purpose, a full-factorial experimental design, representing by far the largest processing window in the literature, was considered, correlating the thermal expansion properties with porosity and hardness. Furthermore, the microstructure and mechanical properties were investigated by scanning electron microscopy and quasi-static tensile tests. Results by means of statistical analysis reveal that a systematic correlation between porosity and CTE properties could not be determined. However, by using specific process parameter combinations, the microstructure changed from a fine-grained fan-like structure to a coarse columnar structure. [ABSTRACT FROM AUTHOR]

In the present work, the influence of defects on the compressive response of octet‐truss AlSi10Mg lattice structure specimens produced with a selective laser melting process is investigated. The defect population in one cell, in two cells, and cubic specimens composed of 27 cells has been assessed with micro‐computed tomography (micro‐CT) analyses. The statistical distributions of the characteristic defect sizes, i.e., the equivalent diameter, the volume, and the surface, assessed in the lattice structure specimens and in volumes randomly extracted from a rectangular bar have been compared. Finally, the compressive behavior of lattice structure specimens has been simulated with a simplified damage‐tolerant finite element model accounting for the influence of defects and compared with experimental results. The analyses have proven that the defect population in volumes extracted from a rectangular bar can provide reliable simulated results, even if micro‐CT inspections of a unit cell or specimens made of several cells are suggested. Highlights: Manufacturing defects strongly influence the structural integrity of lattice structures.Defect volume, surface, and equivalent diameter are reliable characteristic defect sizes.The defect population should be assessed on multiple cells for damage‐tolerant design.Finite element analyses should model the influence of defect size. [ABSTRACT FROM AUTHOR]

Selective laser melting (SLM) is a rapidly evolving technology that requires extensive knowledge and management for broader industrial adoption due to the complexity of phenomena involved. The selection of parameters and numerical analysis for the SLM process are both costly and time-consuming. In this paper, a three-dimensional radial basis function-finite difference (RBF-FD) meshless model is introduced to accurately and efficiently simulate the molten pool size and temperature distribution during the SLM process for austenitic stainless steel (AISI 316L). Two different volumetric moving heat source models were presented, namely the ray-tracing method heat source model and the double-ellipsoidal shape heat source model. The temperature-dependent material properties and phase change process were also considered, based on experiments and effective models. Results of the model for the molten pool size were validated with those of the literature. The proposed approach can be used to predict the effect of different laser power and scan speed on the molten pool size and temperature gradient along the depth direction. The result reveals that the depth of the molten pool is more sensitive to laser power than scan speed. Under the same scan speed, a 22% change in laser power (45 ± 10 W) affects the maximum temperature proportionally by about 9%. The developed algorithm is computationally efficient and suitable for industrial applications. [ABSTRACT FROM AUTHOR]

This study investigated the temperature dependence of IN718 corrosion behavior in 3.5 wt. % NaCl solution, comparing conventionally rolled (Roll) and SLM-manufactured (SLM) samples. While both exhibited degradation with increasing temperature, the Roll sample presented a significantly higher susceptibility to corrosion by increasing the temperature from 25 to 70 °C. Rapid corrosion current density (icorr) of the Roll sample, which increased from 0.25 to 1.3 μA cm2, suggested the preferential γ-matrix dissolution and microgalvanic attack triggered by Laves phases and carbides acting as preferential dissolution sites. Conversely, the SLM sample showcased less segregation and fewer carbide phases due to its high cooling rate, resulting in a milder icorr rise (0.45–0.6 μA cm2). The findings hold promise for a more comprehensive understanding of IN718 performance and can guide the selection of optimal fabrication methods for components exposed to corrosive and high-temperature environments. [ABSTRACT FROM AUTHOR]

Additive manufacturing (AM) technologies enable near-net-shape designs and demand-oriented material usage, which significantly minimizes waste. This points to a substantial opportunity for further optimization in material savings and process design. The current study delves into the advancement of sustainable manufacturing practices in the automotive industry, emphasizing the crucial role of lightweight construction concepts and AM technologies in enhancing resource efficiency and reducing greenhouse gas emissions. By exploring the integration of novel AM techniques such as selective laser melting (SLM) and laser metal deposition (LMD), the study aims to overcome existing limitations like slow build-up rates and limited component resolution. The study's core objective revolves around the development and validation of a continuous process chain that synergizes different AM routes. In the current study, the continuous process chain for DMG MORI Lasertec 65 3D's LMD system and the DMG MORI Lasertec 30 3D's was demonstrated using 316L and 1.2709 steel materials. This integrated approach is designed to significantly curtail process times and minimize component costs, thus suggesting an industry-oriented process chain for future manufacturing paradigms. Additionally, the research investigates the production and material behavior of components under varying manufacturing processes, material combinations, and boundary layer materials. The culmination of this study is the validation of the proposed process route through a technology demonstrator, assessing its scalability and setting a benchmark for resource-efficient manufacturing in the automotive sector. [ABSTRACT FROM AUTHOR]

Aluminum–air batteries are characterized as "green energy for the 21st century" due to their clear advantages in terms of high current discharge, high specific energy, low cost, and easy-to-obtain electrode materials. This study develops the SLM aluminum anode quality prediction model and evaluates its learning and training results using the BP neural network architecture. By altering the network topology of the SLM aluminum anode quality prediction model, we create a process parameter backpropagation model that takes advantage of the extremely adaptable capabilities of artificial neural networks. The quick and exact selection of process parameters meets the goals of density, self-corrosion current, and anode usage, hence improving the forming quality and processing efficiency of SLM aluminum anodes. The experimental results show that the process parameter backpropagation model's parameter configurations match to the real densities and self-corrosion currents, which are somewhat higher than the specified target values. The maximum error rate for the aluminum anode forming quality prediction model is 8.23%. Furthermore, the actual anode utilization rate is somewhat lower than the projected target value, indicating that the backpropagation model can satisfy actual production needs. [ABSTRACT FROM AUTHOR]

Lattice structures have emerged as promising materials for aerospace structure applications due to their high strength-to-weight ratios, customizable properties, and efficient use of materials. These properties make them attractive for use in anti-ice systems, where lightweight and heat exchange are essential. This paper presents an extensive experimental investigation into mechanical compression properties of lattice trusses fabricated from AlSi10Mg powder alloy, a material commonly used in casted aerospace parts. The truss structures were manufactured using the additive manufacturing selective laser melting technique and were subjected to uniaxial compressive loading to assess their performance. The results demonstrate that AlSi10Mg lattice trusses exhibit remarkable compressive strength with strong correlations depending upon both topology and cells' parameters setup. The findings described highlight the potential of AlSi10Mg alloy as a promising material for custom truss fabrication, offering customizable cost-effective and lightweight solutions for the aerospace market. This study also emphasizes the role of additive manufacturing in producing complex structures with pointwise-tailored mechanical properties. [ABSTRACT FROM AUTHOR]

A promising method for additive manufacturing that makes it possible to produce intricate and personalized parts is selective laser melting (SLM). However, the mechanical properties of as-corroded SLM parts are still areas of concern. This research investigates the mechanical behavior of SLM parts that are exposed to a saline environment containing a 3.5% NaCl solution for varying lengths of time. The exposure times chosen for this study were 10 days, 20 days, and 30 days. The results reveal that the tensile strength of the parts is significantly affected by the duration of exposure. Additionally, the study also examined the influence of porosity on the corrosion behavior of the parts. The analysis included studying the mass loss of the parts over time, and a regression analysis was conducted to analyze the relationship between exposure time and mass loss. In addition, the utilization of scanning electron microscopy (SEM) and X-ray photo spectroscopy (XPS) techniques yielded valuable insights into the fundamental mechanisms accountable for the observed corrosion and mechanical behavior. It was found that the presence of corrosion products (i.e., oxide layer) and pitting contributed to the degradation of the SLM parts in the saline environment. This research emphasizes the importance of considering part thickness in the design of SLM components for corrosive environments and provides insights for enhancing their performance and durability. [ABSTRACT FROM AUTHOR]

This study examined the compatibility of an orthopedic implant made from polyamide 12 sintering, coupled with a composite made from Ti6Al4V/ST316L laser fusion, both in vitro and in vivo. SLM 3D printing was used to construct the composite implant of Ti6Al4V/ST316L, while SLS 3D printing was used for the polyamide 12 implant. SEM analysis, X-ray diffraction analysis, and energy dispersive spectroscopy (EDS) were used to characterize the fabricated implants. Mechanical properties of the implants were evaluated using a universal testing machine. Using finite element modeling, von Mises stresses within implants and human bones could be examined. It involved increasing the cell count and implanting MC3T3-E1 preosteoclasts on implants for a week. Biocompatibility was determined using an AlamarBlue® fluorescence test. After six weeks of implantation, rabbit femurs were stained with Hematoxylin and Eosin to determine in vivo biocompatibility of the implant. Based on the findings, both the polyamide 12 implant and the Ti6Al4V/ST316L composite SLM-3D printed by SLS-3D printing were biocompatible. Finite element analysis revealed that the maximum Von Misses stress was within acceptable limits. [ABSTRACT FROM AUTHOR]

This study offers significant insights into the multi-physics phenomena of the SLM process and the subsequent porosity characteristics of ZK60 Magnesium (Mg) alloys. High-speed in-situ monitoring was employed to visualise process signals in real-time, elucidating the dynamics of melt pools and vapour plumes under varying laser power conditions specifically between 40 W and 60 W. Detailed morphological analysis was performed using Scanning-Electron Microscopy (SEM), demonstrating a critical correlation between laser power and pore formation. Lower laser power led to increased pore coverage, whereas a denser structure was observed at higher laser power. This laser power influence on porosity was further confirmed via Optical Microscopy (OM) conducted on both top and cross-sectional surfaces of the samples. An increase in laser power resulted in a decrease in pore coverage and pore size, potentially leading to a denser printed part of Mg alloy. X-ray Computed Tomography (XCT) augmented these findings by providing a 3D volumetric representation of the sample internal structure, revealing an inverse relationship between laser power and overall pore volume. Lower laser power appeared to favour the formation of interconnected pores, while a reduction in interconnected pores and an increase in isolated pores were observed at higher power. The interplay between melt pool size, vapour plume effects, and laser power was found to significantly influence the resulting porosity, indicating a need for effective management of these factors to optimise the SLM process of Mg alloys. [ABSTRACT FROM AUTHOR]

The feasibility of manufacturing high-performance components with complex structures is limited due to cracks in some superalloys fabricated by selective laser melting (SLM). By controlling the main process parameters such as scanning strategy, the adverse effects of cracks can be effectively reduced. In this paper, the effects of two different SLM scanning strategies with island and 'back-and-forth' and post-heat treatment on the cracks and mechanical properties of selective-laser-melted (SLMed) K438 alloy were investigated. The results show that the SLM method of the 'back-and-forth' scanning strategy had better lap and interlayer rotation angles and a more uniform distribution of laser energy compared with the island scanning strategy. The residual stress accumulation was reduced and crack formation was inhibited under this scanning strategy owing to the cooling and shrinkage process. In addition, the dislocation motion was hindered by the formation of uniformly dispersed MC carbides and γ' phases during the SLM K438 alloy process, which resulted in the density of the as-built SLMed K438 alloy being up to 99.34%, the hardness up to 9.6 Gpa, and the tensile strength up to 1309 MPa. After post-heat treatment, the fine secondary γ' phases were precipitated and dispersed uniformly in the Ni matrix, which effectively improved the Young's modulus and tensile strength of the alloy by dispersing the stress-concentrated area. [ABSTRACT FROM AUTHOR]

This study focuses on exploring the application of selective laser melting (SLM) technology in the preparation of titanium‐based nanocomposite materials. By introducing 0.5 wt% graphene oxide (GO) and 7.0% nanomolybdenum (Mo) powder, an attempt is made to improve the microstructure and mechanical properties of titanium alloy materials. The experimental results indicate that the microstructure of the titanium‐based nanocomposite material undergoes significant crystal refinement and phase transition behavior, suggesting a positive role of introducing nanoreinforcing phases in crystal structure regulation. Simultaneously, the introduction of GO significantly improves the thermal conductivity of the material, contributing to more uniform energy transfer and temperature distribution, thereby optimizing the process control of laser melting. In terms of mechanical performance, through microhardness and tensile performance tests, the microhardness of TC4–0.5GO–7Mo increases by ≈30.8% compared with pure TC4. This strengthening effect is primarily attributed to the uniform distribution of GO and Mo powder in the matrix, effectively hindering lattice slip and dislocation movement, enhancing the hardness and tensile properties of the material. Through a comprehensive analysis of microstructure and mechanical properties, not only the mapping relationship between the microstructure and mechanical properties of titanium‐based nanocomposite materials is clarified but also the strengthening mechanism is revealed. [ABSTRACT FROM AUTHOR]

Selective laser melting (SLM) of heat-resistant nickel alloy VZh159 is used to show that at constant energy density the key factor determining the texture and the internal stresses is the hatching distance. At multiple increase in the exposure rate and decrease in the hatching distance, the micropore proportion increases exponentially due to enhancement of the dissipation of the laser radiation caused by reflection in the track overlapping zone. [ABSTRACT FROM AUTHOR]

Analysis of published data on the effect of the exposure algorithms, energy, and scanning speed on the geometric characteristics of the molten pool and its fine structure, on the texture and grain structure of metallic materials synthesized by selective laser melting (SLM) is presented. A regression model describing the correlation between the required laser energy density and the powder composition characteristic temperatures during SLM of heat-resistant nickel- and cobalt-based alloys is obtained. [ABSTRACT FROM AUTHOR]

(1) Background: The aim of this study was to evaluate short- to mid-term clinical and radiological results in patients undergoing primary total hip arthroplasty (THA) with the use of a Selective Laser Melting 3D-printed highly porous titanium acetabular cup (Jump System Traser®, Permedica Orthopaedics). (2) Methods: We conducted a retrospective study and collected prospective data on 125 consecutive patients who underwent primary THA with the use of highly porous titanium cup. Each patient was evaluated preoperatively and postoperatively with a clinical and radiological assessment. (3) Results: The final cohort consisted of 104 patients evaluated after a correct value of 52 (38–74) months. The median Harris Hip Score (HHS) significantly improved from 63.7 (16–95.8) preoperatively to 94.8 (38.2–95.8) postoperatively (p < 0.001), with higher improvement associated with higher age at surgery (β = 0.22, p = 0.025). On postoperative radiographs, the average acetabular cup inclination and anteversion were 46° (30°–57°) and 15° (1°–32°), respectively. All cups radiographically showed signs of osseointegration with no radiolucency observed, or component loosening. (4) Conclusions: The use of this highly porous acetabular cup in primary THA achieved excellent clinical, functional, and radiological results at mid-term follow-up. A better clinical recovery can be expected in older patients. The radiological evaluation showed excellent osseointegration of the cup with complete absence of periprosthetic radiolucent lines. [ABSTRACT FROM AUTHOR]

In order to improve understanding of the fatigue behaviour in additive manufactured samples, this research delves into the challenging interplay between building parameters, particularly fabrication angles, and the presence of pores. The primary objective is to explore the characterisation of these pores and unravel their relationship with the fatigue properties of the material under investigation. Through a systematic analysis of porosity distribution in various fabrication orientations, supplemented by a detailed examination of the elemental dispersion around specific porous structures using energy-dispersive X-ray spectroscopy, a consistent behavioural pattern emerges across the samples. In assessing fatigue behaviour, an examination of the variables reveals that only area and aspect ratio significantly influence the behaviour of the samples. Such studies can contribute substantially to academic research in the field of material science and engineering. [ABSTRACT FROM AUTHOR]

This work presents the results of research conducted with an aim to improve the surface quality, hardness and wear resistance of titanium alloy Ti6Al4V, obtained via the laser powder bed fusion of metals (PBF-LB/M) process of additive manufacturing (AM) known as the 3D printing of metals. The 3D surfaces were coated via reactive electrospark deposition (RESD) with low-pulse energy and electrode materials of low-melting metals and multi-component hard alloys. The relationship between the electrical parameters of the RESD process and the quality, composition, structure, microhardness and wear resistance of the treated surfaces were investigated and analysed. It was found that the roughness and thickness of the resulting surface layers could be changed by changing the RESD modes within the limits of 2.5–5 µm and 8–20 µm, respectively. RESD processing allowed us to achieve two to five times lower roughness than that of titanium AM surfaces. The microhardness and wear resistance of the RESD surfaces are two to four times higher than those of the titanium substrate. Possibilities for the purposeful synthesis of new wear-resistant phases and compounds and for obtaining surface layers with predetermined thickness and roughness were established. It was shown that the subsequent reaction's electrospark processing helped to simultaneously reduce the roughness and increase the hardness and wear resistance of the modified surfaces, and can be successfully used instead of the material-energy-labour and machine-intensive finishing treatments of the titanium surfaces obtained after 3D printing. [ABSTRACT FROM AUTHOR]

Purpose: This paper aims to design a novel TiC/GTD222 nickel-based high-temperature alloy with excellent hot corrosion resistance by incorporating appropriate amounts of C, Al and Ti elements into GTD222 alloy. Design/methodology/approach: The composite material was prepared using the selective laser melting (SLM) technology, followed by a hot isostatic pressing (HIP) treatment. Subsequently, the composite underwent a hot corrosion test in a 75% Na2SO4 + 25% NaCl mixed salt environment at 900 °C. Findings: The HIP-SLMed TiC/GTD222 composite exhibits a relatively low weight loss rate. First, the addition of alloying elements facilitates the formation of multiple protective oxide films rich in Al, Ti and Cr. These oxide films play a crucial role in enhancing the material's resistance to hot corrosion. Second, the HIP treatment results in a reduction of grain size in the composite and an increased number of grain boundaries, which further promote the formation of protective films. Originality/value: The hot corrosion behavior of the TiC/GTD222 nickel-based composite material prepared through SLM and HIP processing has not been previously studied. This research provides a new approach for designing nickel-based superalloys with excellent hot corrosion resistance. [ABSTRACT FROM AUTHOR]

The use of additively manufactured conduits for aerospace applications is currently limited due to the lack of standardized procedures for their characterization under actual operating conditions and the negative impact of high process-related roughness on fluid dynamics. To address these issues, the effect of three scanning strategies on the mechanical performance and surface integrity of additively manufactured Inconel 718 thin-walled nozzles is investigated. The results showcase reductions in roughness of up to 50 % with variations in static strength lower than 1 %. Furthermore, the application of additively manufactured nozzles in realistic scenarios and the potential to outperform conventional manufacturing are demonstrated. [ABSTRACT FROM AUTHOR]

Titanium alloys are an important material for several industries, despite being very energy intensive to produce. This study aims to maximize chip recyclability by adjusting the milling process and subsequent processing steps. The results show that the chip morphology determines the recyclability significantly. Also, a cleaning process is established to reduce chemical contamination. Based on the results a closed-loop material cycle for Ti–6Al–4V powder for additive manufacturing is presented. It is shown that the powder and material properties of printed samples are similar to those of conventional materials, while energy savings of up 77 % can be achieved. [ABSTRACT FROM AUTHOR]

This study focuses on the additive manufacturing technique of selective laser melting (SLM) to produce Ti-6Al-4V-Zn titanium alloy. The addition of zinc at 0.3 wt.% was investigated to improve the strength and ductility of SLM Ti-6Al-4V alloys. The microstructure and mechanical properties were analyzed using different vacuum heat treatment processes, with the 800-4-FC specimen exhibiting the most favorable overall mechanical properties. Additionally, zinc serves as a stabilizing element for the β phase, enhancing the resistance to particle erosion and corrosion impedance of Ti-6Al-4V-Zn alloy. Furthermore, the incorporation of trace amounts of Zn imparts improved impact toughness and stabilized high-temperature tensile mechanical properties to SLM Ti-6Al-4V-Zn alloy. The data obtained serve as valuable references for the application of SLM-64Ti. [ABSTRACT FROM AUTHOR]

Compared to conventional manufacturing, additive manufacturing (AM) of radio frequency (RF) cavities has the potential to reduce manufacturing costs and complexity and to enable higher performance. This work evaluates whether normal conducting side-coupled linac structures (SCCL), used worldwide for a wide range of applications, can benefit from AM. A unit cell geometry (SC) optimized for 75 MeV protons was developed. Downskins with small downskin angles α were avoided to enable manufacturing by laser powder bed fusion without support structures. SCs with different α were printed and post-processed by Hirtisation (R) (an electrochemical process) to minimize surface roughness. The required accuracy for 3 GHz SCCL (medical linacs) is achieved only for α > 45 ∘ . After a material removal of 140 µm due to Hirtisation (R), a quality factor Q 0 of 6650 was achieved. This corresponds to 75% of the Q 0 simulated by CST®. A 3 GHz SCCL concept consisting of 31 SCs was designed. The effective shunt impedance Z T 2 simulated by CST corresponds to 60.13 M Ω m and is comparable to the Z T 2 of SCCL in use. The reduction in Z T 2 expected after Hirtisation (R) can be justified in practice by up to 70% lower manufacturing costs. However, future studies will be conducted to further increase Q 0 . [ABSTRACT FROM AUTHOR]

Selective laser melting (SLM) is an additive manufacturing technique commonly used in the rapid prototyping of components. The complexity of the SLM microstructure poses a unique challenge to deriving effective mechanical properties at different length scales. Representative volume elements (RVEs) are often used to homogenize the material properties of composites. Instead of RVEs, we use statistical volume elements (SVEs) to homogenize the elastic and fracture properties of the material. This relates the inherent variation of a material's microstructure to the variation in its mechanical properties at different observation scales. The convergence to the RVE limit is examined from two perspectives: the stability of the mean value as the SVE size increases for the mean-based approach, and the tendency of the normalized variation in homogenized properties to zero as the SVE size increases for the variation-based approach. Fracture properties tend to make the RVE limit slower than do elastic properties from both perspectives. There are also differences between vertical (normal to printing plane) and horizontal (in-plane) properties. While the elastic properties tend to make the RVE limit faster for the horizontal direction, i.e., having a smaller variation and more stable mean value, the fracture properties exhibit the opposite effect. We attributed these differences to the geometry of the melt pools. [ABSTRACT FROM AUTHOR]

In the work a literature review of materials was conducted, devoted to different areas of studying selective laser melting (SLM) and selective laser sintering (SLS) technologies in order to analyze the processes associated with selective laser deposition occurring during SLM and SLS, as well as the impact of technological measures on the final structure, mechanical and service characteristics of a manufactured part in the additive manufacturing of structural elements on a thin-walled base. The main tasks of research works analyzed in the review were studies focused on the features of structural element formation on a thin-walled base by means of SLM and SLS technologies: modeling of additive manufacturing processes; aspects of planning experiments and manufacturing processes; studying the course of SLM and SLS processes in the given conditions; need in preor post-treatment of material; as well as analysis of the final microstructure and characteristics of samples manufactured using these technologies. Based on the results of literature review, problems were identified and the prospects of using SLM and SLS processes were considered during formation of structural elements on a thin-walled base. A number of aspects were defined, to which it is necessary to pay attention during these studies of SLM and SLS processes when working with a thin-walled base. [ABSTRACT FROM AUTHOR]

This study investigated the effects of Zinc (Zn) content, specifically in the range of 1 wt.% to 7 wt.%, on the powder characteristics, porosity, microstructure, and corrosion behavior of Mg-xZn-0.2Mn alloys produced using selective laser melting (SLM). To evaluate the porosity of the printed parts and various powder attributes, such as size, circularity, void spaces between powders, and inherent imperfections, scanning electron microscopy (SEM) and optical microscopy (OM) were employed. The alloy microstructure, composition, and phase were examined using energy dispersive X-ray (SEM-EDX) and X-ray Diffraction (XRD). The corrosion resistance and degradation behavior were assessed through electrochemical corrosion tests and immersion tests in Hanks' solution at 37.5 °C, respectively. Finally, OM and SEM-EDX were used to characterize the corrosion products. The findings of this study indicated that the powder size increased with Zn content, maintaining a 0.8 circularity. Powder defects were minimal, with occasional satellite particles. For the SLM-printed samples, it was evident that porosity characteristics could be influenced by Zn content. As Zn content increased, the pore fraction rose from 1.0% to 5.3%, and the pore size grew from 2.2 μm to 3.0 μm. All printed samples consisted of an α-Mg matrix. Additionally, a higher Zn content resulted in more distinct grain boundaries. Corrosion resistance decreased with Zn, leading to more pronounced localized corrosion after immersion in Hanks' solution. Ca-P was found as white corrosion products on all samples. [ABSTRACT FROM AUTHOR]

For the application of high-performance titanium alloy parts in the additive manufacturing of aerospace, automotive and other fields, titanium matrix composites reinforced by TiBw were fabricated using selective laser melting technology. The influence of different energy densities on the microstructure, microhardness and tribological performance of TiBw/Ti6Al4V composite were studied, and the formation and evolution mechanism of the unique microstructure was analyzed. It is found that the TiBw/Ti6Al4V composite fabricated by SLM is mainly composed of a fine α′-Ti matrix, nano-scale TiBw produced by the in-situ reaction and residual TiB 2 particles. The size, morphology and distribution of TiBw and its aggregated network structure are related to laser energy density. As the energy density increases, the morphology of TiBw evolves from tiny acicular to thick rod-like or plate-like. Additionally, the network chain composed of TiBw gradually expands or even breaks. Compared with Ti6Al4V alloy processed by SLM and traditional casting, the microhardness and wear resistance of TiBw/Ti6Al4V composites fabricated under various energy densities are significantly improved, and the friction process is affected by the abrasive wear, adhesive wear, and oxidation wear mechanisms. The good tribological performance is attributed to the fine-grain strengthening of Ti matrix and the second-phase strengthening effect caused by the network structure of TiBw. [ABSTRACT FROM AUTHOR]

Ti-based metallic glasses have a high potential for implant applications. The feasibility of a new biocompatible Ti-based bulk metallic glass composite for selective laser melting (SLM) had been examined. Therefore, it is necessary to design a high-glass-forming-ability Ti-based metallic glass (∆Tx = 81 K, γ = 0.427, γm = 0.763), to fabricate a partial glass-formable spherical powder (the volume fraction of the amorphous phase in the atomized Ti-based powders being 73% [size < 25 μm], 61% [25–37 μm], and 50% [37–44 μm]), and establish an SLM parameter (a scan rate of 600 mm/s, a power of 120 W, and an overlap of 10%). The Ti42Zr35Si5Co12.5Sn2.5Ta3 bulk metallic glass composite was successfully fabricated through SLM. This study demonstrates that the TiZrSiCoSnTa system constitutes a promising basis for the additive manufacturing process in terms of preparing biocompatible metallic glass composites into complicated graded foam shapes. [ABSTRACT FROM AUTHOR]

In this paper, the influence of a blunt notch on the VHCF response of SLM Ti6Al4V specimens is investigated. Ultrasonic fully reversed tension–compression tests up to 109 cycles were carried out on unnotched specimens and specimens with a blunt notch. Unnotched specimens show a slightly larger fatigue response, with limited differences. All fatigue failures originated from defects, which are bigger in unnotched specimens, mainly due to the different risk volume of the tested specimens and the related size effect. Interactions between notch, stress gradient, and defect size distribution must be considered to properly assess the influence of notch on the VHCF response. Highlights: The influence of a blunt notch on the VHCF response of SLM Ti6Al4V alloy is investigated.The feasibility of ultrasonic VHCF tests on SLM Ti6Al4V specimens is proved.Surface defects play a major role even in SLM specimens with blunt notches.Defects and related size effect can limit the stress concentration effect. [ABSTRACT FROM AUTHOR]

A systematic study was conducted to investigate the distinct mechanisms involved in the formation of the inner surfaces of cylindrical and parallelepipedic-shaped structures. The surface roughness, flatness, and sinking distance were used as key indices to measure the quality of overhanging surfaces, while the surface flatness and roughness were used to evaluate the quality of the side and bottom surfaces of the inner hole. The inner surface morphology was observed using a scanning electron microscope and a white light interferometer. The test results show that the quality of the overhanging surface had a significant impact on the quality of the parallelepipedic-shaped inner hole. In contrast, the cylindrical-shaped inner hole had a shorter but more uniformly distributed overhanging surface, resulting in a different behavior of the overhanging and side surface quality. An improved model of the overhanging surface was established by combining all of the above results and comparing them with the traditional Euler Bernoulli beam model. The factors affecting the quality of the overhanging surface were analyzed, and measures for improving the quality of the overhanging surface during the SLM manufacturing process were proposed. [ABSTRACT FROM AUTHOR]

This paper aims to review some important microstructural defects arising in the alloys manufactured by selective laser melting (SLM) or laser powder bed fusion (LPBF). During the manufacturing process, various defects can occur in metals, which can negatively impact their mechanical properties and structural integrities. These defects include gas pores, lack of fusions, keyholes, melt pools, cracks, inclusions, and segregations. In this review, heterogeneities such as inclusion and segregation defects are discussed. Other types of defects have been comprehensively discussed in other reviews. Inclusions refer to foreign ceramic particles that are present within the metal, whereas segregations refer to the uneven distribution of alloying elements within the microstructure of the metal. The cause of appearance, effect of different parameters, and methods to reduce them in the final part are also reviewed. The effects of these defects on the integrity of the produced parts are discussed. Solutions for the elimination or minimization of these defects are also suggested. Post treatments and modifications of an alloy's composition can also help to improve its material properties and reduce its defect concentration. [ABSTRACT FROM AUTHOR]

The demand for orthopedic implants is increasing, driven by a rising number of young patients seeking an active lifestyle post-surgery. This has led to changes in manufacturing requirements. Joint arthroplasty operations are on the rise globally, and recovery times are being reduced by customized endoprostheses that promote better integration. Implants are primarily made from metals and ceramics such as titanium, hydroxyapatite, zirconium, and tantalum. Manufacturing processes, including additive manufacturing and thermal plasma spraying, continue to evolve. These advancements enable the production of tailored porous implants with uniform surface coatings. Coatings made of biocompatible materials are crucial to prevent degradation and enhance biocompatibility, and their composition, porosity, and roughness are actively explored through biocompatibility testing. This review article focuses on the additive manufacturing of orthopedic implants and thermal plasma spraying of biocompatible coatings, discussing their challenges and benefits based on the authors' experience with selective laser melting and microplasma spraying of metal-ceramic coatings. [ABSTRACT FROM AUTHOR]

There is a fast-growing interest in the use of selective laser melting (SLM) for metal/alloy additive manufacturing. Our current knowledge of SLM-printed 316 stainless steel (SS316) is limited and sometimes appears sporadic, presumably due to the complex interdependent effects of a large number of process variables of the SLM processing. This is reflected in the discrepant findings in the crystallographic textures and microstructures in this investigation compared to those reported in the literature, which also vary among themselves. The as-printed material is macroscopically asymmetric in terms of both structure and crystallographic texture. The <101> and <111> crystallographic directions align parallel with the SLM scanning direction (SD) and build direction (BD), respectively. Likewise, some characteristic low-angle boundary features have been reported to be crystallographic, while this investigation unequivocally proves them to be non-crystallographic, since they always maintain an identical alignment with the SLM laser scanning direction, irrespective of the matrix material's crystal orientation. There are also 500 ± 200 nm columnar or cellular features, depending on the cross-section, which are generally found all over the sample. These columnar or cellular features are formed with walls made of dense packing of dislocations entangled with Mn-, Si- and O-enriched amorphous inclusions. They remain stable after ASM solution treatments at a temperature of 1050 °C, and therefore, are capable of hindering boundary migration events of recrystallization and grain growth. Thus, the nanoscale structures can be retained at high temperatures. Large 2–4 μm inclusions form during the solution treatment, within which the chemical and phase distribution are heterogeneous. [ABSTRACT FROM AUTHOR]

This work aimed to comprehensively evaluate the influence of different surface modifications on the surface roughness of Ti6Al4V alloys produced by selective laser melting (SLM), casting and wrought. The Ti6Al4V surface was treated using blasting with Al2O3 (70–100 µm) and ZrO2 (50–130 µm) particles, acid etching with 0.017 mol/dm3 hydrofluoric acids (HF) for 120 s, and a combination of blasting and acid etching (SLA). It was found that the optimization of the surface roughness of Ti6Al4V parts produced by SLM differs significantly from those produced by casting or wrought processes. Experimental results showed that Ti6Al4V alloys produced by SLM and blasting with Al2O3 followed by HF etching had a higher surface roughness (Ra = 2.043 µm, Rz = 11.742 µm), whereas cast and wrought Ti6Al4V components had surface roughness values of (Ra = 1.466, Rz = 9.428 m) and (Ra = 0.940, Rz = 7.963 m), respectively. For Ti6Al4V parts blasted with ZrO2 and then etched by HF, the wrought Ti6Al4V parts exhibited higher surface roughness (Ra = 1.631 µm, Rz = 10.953 µm) than the SLM Ti6Al4V parts (Ra = 1.336 µm, Rz = 10.353 µm) and the cast Ti6Al4V parts (Ra = 1.075 µm, Rz = 8.904 µm). [ABSTRACT FROM AUTHOR]

The AISI 316L austenitic stainless steel fabricated by selective laser melting (SLM) is considered to have great prospects for applications in nuclear systems. This study investigated the He-irradiation response of SLM 316L, and several possible reasons for the improved He-irradiation resistance of SLM 316L were systematically revealed and evaluated by using TEM and related techniques. The results show that the effects of unique sub-grain boundaries have primary contributions to the decreased bubble diameter in SLM 316L compared to that in the conventional 316L counterpart, while the effects of oxide particles on bubble growth are not the dominant factor in this study. Moreover, the He densities inside the bubbles were carefully measured using electron energy loss spectroscopy (EELS). The mechanism of stress-dominated He densities in bubbles was validated, and the corresponding reasons for the decrease in bubble diameter were freshly proposed in SLM 316L. These insights help to shed light on the evolution of He bubbles and contribute to the ongoing development of the steels fabricated by SLM for advanced nuclear applications. [ABSTRACT FROM AUTHOR]

Experimental results of microstructural studies of refractory nickel alloys obtained by selective laser melting under different crystallization conditions are systematized. The dendritic (cellular) structure and the distribution of the alloying elements in the volume of dendrite arms are studied by scanning and transmission electron microscopy. The detected microsegregation matches a normal crystallization law and is caused by concentration supercooling. It is shown that the main factors responsible for formation of the fine structure of a track are the orientation growth (epitaxy) and the competitive growth of crystallites. The orientation of the crystallites is transferred not only by the first-order arms but also by the second-order arms, and a specific direction is implemented upon coincidence of the crystallographic orientation of the crystallite with the radial direction of the heat removal. The increasing complexity and the fragmentation of the fine structure are associated with the mechanism of stochastic binarization of the crystallographic orientation implemented upon partial remelting and opening of fragments of cells in the current and preceding layers. [ABSTRACT FROM AUTHOR]

In this study, Ti-22Al-25Nb intermetallic compound alloys are fabricated through selective laser melting (SLM) at four scanning speeds (600, 700, 800, and 900 mm/s). The microstructure and mechanical properties of the selective laser melting fabricated alloys are systematically evaluated. The results indicate that scanning speed significantly affects microstructure characteristics (e.g., relative density, grain size, texture density, and the precipitation of secondary phases). The variation laws of the relative density, grain size, and texture density are likewise affected by scanning speed. The relative density, grain size, and texture density increase and then decrease with the increase in scanning speed. The alloy fabricated with the lowest scanning speed (600 mm/s) exhibits the maximum relative density, grain size, and texture density. By contrast, the alloy with the highest scanning speed (900 mm/s) exhibits the minimum relative density, grain size, and texture density. Furthermore, the precipitations of the O phase and Ti3Al phase are primarily distributed in regions with a high strain concentration near the pool boundary. The alloy fabricated with a 600 mm/s scanning speed simultaneously achieves the highest strength and elongation, which is closely correlated with the uniform distribution of secondary phases. [ABSTRACT FROM AUTHOR]

The optimal SLM conditions of 304L stainless steel were obtained by single factor and orthogonal tests. Results indicated that the optimal hardness (75 HRB) and Relative Density (RD 99.24%) could be obtained when the laser output power was 190 W, the scanning distance was 0.09 mm and the scanning speed was 800 mm/s. The microstructure of fish scales was uniform and compact with a few pores in the optimal sample. The fine particles were randomly distributed near the edge of the molten pool, and some preferred granular columnar crystal structures were formed. Abundant entanglement dislocations were observed between cell structures, forming dislocation clusters. Spherical nano-precipitates, rich in Si, Mn, and O, were also observed near cell structures. The mechanical properties of the specimens were highly anisotropic, and there were obvious necking and ductility at the tensile fracture. [ABSTRACT FROM AUTHOR]

Ti-6Al-4V is an α+β phase Ti alloy which is widely used because of its microstructural features. Complex three-dimensional (3-D) parts can be created directly from computer models by selectively melting (SLM) the metal powder using additive manufacturing (AM) technology. In this present work hot corrosion experiments were performed on the selective laser melted sample and as received sample in laboratory air and NaCl environment at 600°C for 50 cycles. The parabolic rate constants were calculated for different environments from the thermogravimetric data obtained for the samples and they show that corrosion rate is minimum in laboratory air and maximum for SLM sample in NaCl environment due to the presence of gaseous chlorides. The microstructure morphologies and the oxide scales formed upon hot corrosion was characterized by optical and scanning electron microscope (SEM) while the constituents were determined with energy-dispersive X-ray (EDX) analysis to understand the corrosion mechanisms. The high corrosion rate of SLM compared to the as-received sample was studied by analysing the area percentage of porosity. Since helicopters and planes are used in sea areas this work is practically important in the aeronautical field. [ABSTRACT FROM AUTHOR]

To improve the performance of selective laser melted 316L stainless steel components the effects of laser power and heat treatment methods on the surface morphology and mechanical properties of the formed parts are studied. The research results show that with the increase of the laser power, the surface morphology quality and mechanical properties of the formed parts initially increase and then decrease. When the laser power is 170 W a formed part with better surface morphology and mechanical properties can be obtained. The grain size and elongation can be increased by heat treating the formed part. Among them, the air cooling method can obtain better mechanical properties than the water cooling method. The combination of laser power and heat treatment is a promising method to improve the performance of selected laser melted 316L stainless steel parts. [ABSTRACT FROM AUTHOR]

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In recent years, bone defect and bone tissue damage have become common clinical diseases. The development of bionic bone has had an important impact on the repair and reconstruction of bone tissue. Porous scaffolds have the advantages of adjustable pore size and controllable shape, which can solve the problem of mismatch in the process of bone repair, but traditional processing methods cannot overcome the challenge of the preparation of complex porous scaffolds. Therefore, 316L porous stainless steel scaffolds with different pore sizes (200 μm, 300 μm, 400 μm and 500 μm, respectively) were prepared by selective laser melting. Stress and strain were simulated and analyzed by using a finite element simulation method. Combined with a heat treatment experiment, a hardness test, a metallographic observation and a compression test, porous scaffolds were studied. The mechanical properties and microstructures of the scaffolds were studied and analyzed, and the optimized porous scaffolds were obtained. With reasonable melting parameters, the porous scaffolds that could meet the mechanical property requirements of load-bearing bone restorations were prepared by SLM. [ABSTRACT FROM AUTHOR]

Electrolyte plasma polishing (EPP) is an innovative and efficient technology mainly used to polish complex metal products and obtain surfaces with low roughness and high gloss. However, limited by the electrolyte bath size, EPP method is not suitable for polishing workpieces with large size. This paper introduces a spray electrolyte plasma polishing (SEPP) method that can process large-scale and complex surface. The theoretical mechanism of SEPP is presented. GH3536 superalloy plates manufactured by SLM were used as the experimental specimens. The influence of cathode feed velocity on surface roughness is studied. Key parameters, like distance between anode and cathode, voltage, temperature, and flow rate of the electrolyte were investigated experimentally. Properties such as surface roughness, micro morphology, chemical composition, and surface hardness of the GH3536 specimens were detected and analyzed. The results show that SEPP technology can decrease the specimen surface roughness from Ra = 13.93 μm to 0.107 μm and obtain a smooth and glossy surface without obvious machining traces. The oxides and other impurities on the specimen surface were removed, and the contents of Ni, Cr, and Fe elements were increased. Additionally, the surface hardness values of the polished specimen were increased and showed good consistency. [ABSTRACT FROM AUTHOR]

It was found that stress displayed an oscillating pattern due to the discontinuous sliding process in samples under compressive loading on diamond Ti6Al4V lattice structure with shells. A simple model used for calculating relative density of diamond lattice structure was proposed and evaluated. Moreover, theoretical models with better precision were suggested to estimate the elastic modulus and yield strength of lattice structures without considering the shells. Besides, a quantitative model was suggested to describe the shell effect on elastic modulus of lattices structures and validated to be acceptable by comparing with current experimental results. [ABSTRACT FROM AUTHOR]

In 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. [ABSTRACT FROM AUTHOR]

Laser powder bed fusion (L-PBF) was used to produce stator half-shells of a transverse flux machine from pure iron (99.9% Fe). In order to reduce iron losses in the bulk components, radially extending slits with a nominal width of 150 and 300 µm, respectively, were integrated during manufacturing. The components were subjected to a suitable heat treatment. In addition to a microscopic examination of the slit quality, the iron losses were also measured using both a commercial and a self-developed measurement setup. The investigations showed the iron losses can be reduced by up to 49% due to the integrated slits and the heat treatment. [ABSTRACT FROM AUTHOR]

In this work, a literary review of the materials devoted to different directions of research of slm technology was made, 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. 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 defocusing amount; study of modes and methods of slm processing, as well as final microstructure of the specimens; 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 application is substantiated. [ABSTRACT FROM AUTHOR]

Hastelloy X is a typical solid solution strengthening superalloy featured by good tolerance against oxidation and adequate mechanical and creep properties at 900 °C. However, current works about Ni‐based superalloys mainly focus on the relationship between microstructure and mechanical performance at high‐temperature regions, leaving the failure mechanism under the circumstance of oxidation as an open issue. Herein, the effects of the microstructure on the high‐temperature oxidation behavior and mechanical properties of Hastelloy X alloys prepared by selective laser melting (SLM) technique and hot isostatic pressing (HIP), respectively, are investigated. The experimental results show the existence of a large number of microcracks in the SLM samples during oxidation at 900 °C, which can contribute to increased oxidation weight gain and ease of oxide layer exfoliation. With the assistance of HIP, thermal cracks are effectively eliminated by the combination of better elemental homogeneity. The further improvement of oxidation resistance is found to result from the densification of Cr2O3 particles and the hindrance of oxygen diffusion. From the perspective of the application, this work provides valuable support for the explanations of the oxidation resistance and fracture mechanism of Hastelloy X superalloys in high‐temperature service environments. [ABSTRACT FROM AUTHOR]

Additive manufacturing makes the production of bulk metallic glasses possible in thicknesses exceeding the critical casting thickness. However, a crucial challenge is the build-up of thermally induced stress, often resulting in printed parts suffering from cracking. In this study, the process parameters are optimised for printing soft-magnetic metallic glass samples of an Fe-based alloy (Fe 73.8 P 10.6 Mo 4.2 B 2.3 Si 2.3 C 6.7), using laser beam powder bed fusion. In addition, the structural and magnetic properties of as-received and heat-treated powder are investigated and compared to those of the printed samples. Kerr microscopy is used for imaging the magnetic domains on single track cross-sections produced on top of a polished printed sample. This reveals the shape of the melt pool of a single laser track, as well as the magnetic domains around it and in other regions of the printed sample. The shape and size of the magnetic domains reflect the residual stress in the sample through the effect of magneto-elastic coupling. This magnetic contrast could be used to get further insights into how to control the development of stress during the printing process. • Laser beam powder bed fusion printing parameters suitable for producing Fe-P-Mo-B-Si-C metallic glass parts was established. • The printed parts are X-ray amorphous and soft-magnetic, with low magnetic coercivity. • Cross-sections of printed parts, single track melt pools, and their associated stress were imaged using Kerr microscopy. • The magnetic domain profile of the melt pool indicates compressive stress inside the melt pool and tensile stress around it. [ABSTRACT FROM AUTHOR]

In metal 3D printing with Selective Laser Melting (SLM) technology, due to large thermal gradients, the residual stress (RS) distribution is complicated to predict and control. RS can distort the shape of the components, causing severe failures in fabrication or functionality. Thus, several research papers have attempted to quantify the RS by designing geometries that distort in a predictable manner, including the Bridge Curvature Method (BCM). Being different from the existing literature, this paper provides a new perspective of the RS build-up in aluminum parts produced with SLM using a combination of experiments and simulations. In particular, the bridge samples are printed with AlSi10Mg, of which the printing process and the RS distribution are experimentally assessed with the Hole Drilling Method (HDM) and simulated using ANSYS and Simufact Additive. Subsequently, on the basis of the findings, suggestions for improvements to the BCM are made. Throughout the assessment of BCM, readers can gain insights on how RS is built-up in metallic 3D-printed components, some available tools, and their suitability for RS prediction. These are essential for practitioners to improve the precision and functionality of SLM parts should any post-subtractive or additive manufacturing processes be employed. [ABSTRACT FROM AUTHOR]

The fabrication of polymer–metal hybrids in an additive process makes it possible to further improve the geometrical and material adaption in a multi-material design. In this work, PLA is fabricated through a fused filament fabrication process on AlSi10Mg structures manufactured by laser powder bed fusion. The mechanical connection is realised by form fit, for which different geometries are examined through tensile tests. Deep penetration of the PLA into the metallic structures is achieved by optimisation of the process parameters. The penetration depth is assessed through the use of micro-computed tomography. Finally, the interplay of mechanisms leading to a firm connection is discussed. [ABSTRACT FROM AUTHOR]