Review

Materials’ Fundamental Issues of Laser Additive Manufacturing for High-performance Large Metallic Components

  • WANG Huaming
Expand
  • Research & Application Center of National Defense Industries on Laser Additive Manufacturing, Key Laboratory of Aerospace Materials and Performance of Ministry of Education, School of Materials Science and Engineering, Beihang University, Beijing 100191, China

Received date: 2014-07-22

  Revised date: 2014-08-05

  Online published: 2014-08-08

Supported by

National Basic Research Program of China(2011CB606305-2, 2010CB731705); National High Technology Research and Development Program of China (SS2014AA041701)

Abstract

The advantages, state of the art and technological challenges of laser melting deposition additive manufacturing for high-performance large metallic components are briefly reviewed. The unique technological merits of laser additive manufacturing for high-performance large metallic components characterized by digital integration of "advanced materials processing", "complex structure direct manufacturing" and "controlling shape and performance" are systematically discussed. It is emphasized that further development and industrial applications of the revolutionary manufacturing technology will greatly rely on the intensive basic research on those general non-equilibrium materials fundamental issues inherent to the additive manufacturing process such as laser/metal interaction behavior and laser absorbing mechanisms, forming mechanisms and mechanical behavior of internal metallurgical defects, constrained rapid solidification kinetics of moving melt-pool and grain morphological selection characteristics of deposited components, non-steady cyclic solid-state phase transformation kinetics and microstructure formation behavior, non-linear thermal history/thermal stress coupling behavior and distortion and cracking, etc.

Cite this article

WANG Huaming . Materials’ Fundamental Issues of Laser Additive Manufacturing for High-performance Large Metallic Components[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2014 , 35(10) : 2690 -2698 . DOI: 10.7527/S1000-6893.2014.0174

References

[1] Lu B H, Li D C. Development of the additive manufacturing (3D printing) technology[J]. Mechanical Building and Automation, 2013, 42(4): 1-4. (in Chinese) 卢秉恒, 李涤尘. 增材制造(3D打印)技术发展[J]. 机械制造与自动化, 2013, 42(4): 1-4.

[2] Arcella F G, Froes F H. Producing titanium aerospace components from powder using laser forming[J]. JOM, 2000, 52(5): 28-30.

[3] Wang H M, Zhang S Q, Wang X M. Progress and challenges of laser direct manufacturing of large titanium structural components[J]. Chinese Journal of Lasers, 2009, 36(12): 3204-3209. (in Chinese) 王华明, 张述泉, 王向明. 大型钛合金结构件激光直接制造的进展及挑战[J]. 中国激光, 2009, 36(12): 3204-3209.

[4] Breinan E M, Kear B H. Rapid solidification laser processing at high power density[J]. Materials Processing-Theory and Practices, 1983, 3: 235-295.

[5] US National Science and Technology Council. National network for manufacturing innovation: a preliminary design [EB/OL]. (2013-01-10)[2014-07-22]. http://www.whitehouse.gov/sites/default/files/microsites/ostp/nstc_nnmi_prelim_design_final.pdf.

[6] Gamann M, Bezencon C, Canalis P, et al. Single-crystal laser deposition of super-alloys: processing-microstructure maps[J]. Acta Materialia, 2001, 49(6): 1051-1062.

[7] Dinda G P, Dasgupta A K, Mazumder J. Laser aided direct metal deposition of Inconel 625 superalloy: Microstructural evolution and thermal stability[J]. Materials Science and Engineering: A, 2009, 509(1-2): 98-104.

[8] Hussein N I S, Segal J, McCartney D G, et al. Micro-structure formation in Waspaloy multilayer builds following direct metal deposition with laser and wire[J]. Materials Science and Engineering: A, 2008, 497(1-2): 260-269.

[9] Moata R J, Pinkerton A J, Li L, et al. Residual stresses in laser direct metal deposited Waspaloy[J]. Materials Science and Engineering: A, 2011, 528(6): 2288-2298.

[10] Susana D, Puskar J D, Brooks J A, et al. Quantitative characterization of porosity in stainless steel LENS powders and deposits[J]. Materials Characterization, 2006, 57(1): 36-43.

[11] Wang L, Felicelli S D, Pratt P. Residual stresses in LENS-deposited AISI 410 stainless steel plates[J]. Materials Science and Engineering: A, 2008, 496(1-2): 234-241.

[12] Yu J, Rombouts M, Maes G. Cracking behavior and mechanical properties of austenitic stainless steel parts produced by laser metal deposition[J]. Materials and Design, 2013, 45: 228-235.

[13] Amano R S, Rohatgi P K. Laser engineered net shaping process for SAE 4140 low alloy steel[J]. Materials Science and Engineering: A, 2011, 528(22-23): 6680-6693.

[14] Kadiri H E, Wang L, Horstemeyer M F, et al. Phase transformations in low-alloy steel laser deposits[J]. Materials Science and Engineering: A, 2008, 494(1-2): 10-20.

[15] Milewski J O, Thoma D J, Fonseca J C, et al. Development of a near net shape processing method for rhenium using directed light fabrication[J]. Materials and Manufacturing Process, 1998, 13(5): 719-730.

[16] Boyer R R. An overview of titanium use in the aerospace industry[J]. Materials Science and Engineering: A, 1996, 213(1-2): 103-114.

[17] Kear B H, Breinan E M. Layerglazing, a new process for production and control of rapidly chilled metallurgical microstructure[J]. Metals Technology, 1979, 6(4):121-129.

[18] Baufeld B, Brandl E, van der Biest O. Wire based additive layer manufacturing: Comparison of micro-structure and mechanical properties of Ti-6Al-4V components fabricated by laser-beam deposition and shaped metal deposition[J]. Journal of Materials Processing Technology, 2011, 211(6): 1146-1158.

[19] Brandl E, Palm F, Michailov V, et al. Mechanical properties of additive manufactured titanium (Ti-6Al-4V) blocks deposited by a solid-state laser and wire[J]. Materials and Design, 2012, 32(10): 4665-4675.

[20] Gockel J, Beuth J. Understanding Ti-6Al-4V micro structure control in additive manufacturing via process maps[C]//24th International SFF Symposium-An Additive Manufacturing Conference. Austin, TX, 2013: 666-674.

[21] Clark D, Whittaker M, Bache M R. Microstructural characterization of a prototype titanium alloy structure processed via direct laser deposition (DLD)[J]. Metallurgical and Materials Transactions: B, 2012, 43(2): 388-396.

[22] Wang F D, Williams S, Colegrove P, et al. Microstructure and mechanical properties of wire and arc additive manufactured Ti-6Al-4V[J]. Metallurgical and Materials Transactions: A, 2013, 44(2): 968-977.

[23] Arcella F G, Abbott D H, House M A, et al. Titanium alloy structures for airframe applications by the laser forming process[C]//41st Structures, Structural Dynamics, and Materials Conference and Exhibit. Atlanta, GA, 2000: 1465-1473.

[24] Abbott D. AeroMet implementing novel Ti process[J]. Metal Powder Report, 1998, 53(2): 24-26.

[25] Keicher D M, Smugeresky J E. The laser forming of metallic components using particulate materials[J]. JOM, 1997, 49(5): 51-54.

[26] Kobryn P A, Semiatin S L. The laser additive manufacture of Ti-6Al-4V[J]. JOM, 2001, 53(9): 40-42.

[27] Santos E C, Shiomi M, Osakada K, et al. Rapid manufacturing of metal components by laser forming[J]. International Journal of Machine Tools and Manufacture, 2006, 46(12-13): 1459-1468.

[28] He R, Wang H M. Fatigue crack nucleation and propagation behaviors of laser melting deposited Ti-6Al-2Zr-Mo-V alloy[J]. Materials Science and Engineering: A, 2010, 527(7-8): 1933-1937.

[29] Liu C M, Wang H M, Tian X J, et al. Subtransus triplex heat treatment of laser melting deposited Ti-5Al-5Mo-5V-1Cr-1Fe near beta titanium alloy[J]. Materials Science and Engineering: A, 2014, 590: 30-36.

[30] Zhang S, Lin X, Huang W D, et al. Heat treatment microstructure and mechanical properties of laser solid forming Ti-6Al-4V alloy[J]. Rare Metals, 2009, 28(6): 537-544.

[31] Li J, Wang H M. Microstructure and mechanical properties of rapid directionally solidified Ni-base superalloy Rene 41 by laser melting deposition manufacturing[J]. Materials Science and Engineering: A, 2010, 527(18-19): 4823-4829.

[32] Zhang Y W, Zhang S Q, Wang H M. Microstructure and mechanical properties of directional rapidly solidified Ni-base superalloy Rene95 by laser melting deposition manufacturing[J]. Rare Metal Materials and Engineering, 2008, 37(1): 169-172. (in Chinese) 张亚玮, 张述泉, 王华明. 激光熔化沉积定向快速凝固高温合金组织与性能[J]. 稀有金属材料与工程, 2008, 37(1): 169-172.

[33] Liu F, Lin X, Leng H, et al. Microstructure changes in a laser solid forming Inconel 718 superalloy thin wall in the deposition direction[J]. Optics and Laser Technology, 2013, 45: 330-335.

[34] Ma M M, Wang Z M, Zeng X Y, et al. Control of shape and performance for direct laser fabrication of precision large-scale metal parts with 316L stainless steel[J]. Optics and Laser Technology, 2013, 45: 209-216.

[35] Lu Z L, Li D C, Lu B H, et al. Investigation into the direct laser forming process of steam turbine blade[J]. Optics and Laser in Engineering, 2011, 49(9-10): 1101-1110.

[36] Zhang Y J, Yu G, He X L, et al. Numerical and experimental investigation of multilayer SS410 thin wall built by laser direct metal deposition[J]. Journal of Materials Processing Technology, 2012, 212(1): 106-112.

[37] Song M H, Lin X, Huang W D, et al. Influence of forming atmosphere on the deposition characteristics of 2Cr13 stainless steel during laser solid forming[J]. Journal of Materials Processing Technology, 2014, 214(3): 701-709.

[38] Yan M, Zhang S Q, Wang H M. Solidification microstructure and mechanical properties of corrosion-resistant ultrahigh strength steel AerMet 100 fabricated by laser melting deposition[J]. Acta Metallurgica Sinica, 2007, 43(5): 472-476. (in Chinese) 颜敏, 张述泉, 王华明. 激光熔化沉积AerMet 100耐蚀超高强度钢的凝固组织及力学性能[J]. 金属学报, 2007, 43(5): 472-476.

[39] Dong C, Zhang S Q, Li A, et al. Microstructure of ultrahigh strength steel 300M fabricated by laser melting deposition[J]. Acta Metallurgica Sinica, 2008, 44(5): 598-602. (in Chinese) 董翠, 张述泉, 李安, 等. 激光熔化沉积300M超高强度钢的显微组织[J]. 金属学报, 2008, 44(5): 598-602.

[40] Zhong M L, Liu W J, Ning G Q, et al. Laser direct manufacturing of tungsten nickel collimation component[J]. Journal of Materials Processing Technology, 2004, 147(2): 167-173.

[41] Wang Y D, Tang H B, Wang H M, et al. Microstructure and mechanical properties of laser meting deposited 1Cr12Ni2WMoVNb steel[J]. Materials Science and Engineering: A, 2010, 527(18-19): 4804-4809.

[42] Qu H P, Wang H M. Microstructure and mechanical properties of laser meting deposited gamma-TiAl intermetallic alloys[J]. Materials Science and Engineering: A, 2007, 466(1-2): 187-194.

[43] Xu X, Lin X, Huang W D, et al. Microstructure evolu-tion of laser solid forming of Ti-50wt% Ni alloy[J]. Journal of Alloys and Compounds, 2009, 480(2): 782-787.

[44] Liu D, Zhang S Q, Wang H M, et al. Microstructure and tensile properties of laser melting deposited TiC/TA15 titanium matrix composites[J]. Journal of Alloys and Compounds, 2009, 485(1-2): 156-162.

[45] Lin X, Yue T M, Huang W D, et al. Microstructure and phase evolution in laser rapid forming of a functionally graded Ti-Rene88DT alloy[J]. Acta Materialia, 2006, 54(7): 1901-1915.

[46] Qu H P, Zhang S Q, Li A, et al. Microstructure and mechanical properties of laser melting deposition (LMD) Ti/TiAl structural gradient material[J]. Materials and Design, 2010, 31(1): 574-582.

Outlines

/