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Microstructure and Physical Properties of Additive Manufactured Alloys

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 April 2022) | Viewed by 11335

Image courtesy of Dr. Ori Yeheskel

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Dr. Ori Yeheskel

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Materials Engineering Department, Ben Gurion University, Be’er Sheva 8410501, Israel
Interests: powder technology; HIP; ceramics; metals; elastic moduli; additive manufacturing

Special Issue Information

Dear Colleagues,

Additive Manufacturing (AM) is in a stage where the sales of powder bed fusion (PBF) production machines exceed 1500 a year as of 2019¹. The share of the PBF machines is 85% of the sales market. This indicates that the reliability of machine production is high. In order to further increase the AM market, the share of high-quality products should turn into the lion’s share. However, developing materials and products using advanced technologies, such as AM, is a complex process which requires a deep understanding of the processing–microstructure–properties relationships.

Many metallic products are being developed using the variety of AM methods available today. Among these methods, there is PBF with heat source of either laser (L-PBF) or electron beam melting (PB-EBM), direct energy deposition (DED), binder jetting (BJ), wire + arc AM (WAAM), plates bonding using ultrasounds (USAM), and more. The products manufactured using these methods consist mainly of metallic alloys and composites. There are myriad processing parameters which affect the microstructure and physical properties of the printed material.

In this Special Issue, we focus on the relation between the microstructure and physical properties of metallic alloys and composites at a wide temperature range. The physical properties include, on one hand, mechanical properties like strength, elongation, and fatigue life and, on the other hand, thermal properties such as thermal conductivity and thermal diffusivity, thermal expansion, as well as electrical conductivity and more.

It is my pleasure to invite you to submit a manuscript to this Special Issue. Full papers, communications, and reviews are all welcome.

¹ AMPOWER Management Report 2020, Metal Additive Manufacturing, Machine Sales Forecast PBF

Dr. Ori Yeheskel
Guest Editor

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Keywords

microstructure
thermophysical properties
thermomechanical properties
fatigue
metallic alloys

Published Papers (4 papers)

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Research

26 pages, 8411 KiB

Open AccessFeature PaperArticle

Measurement of the Anisotropic Dynamic Elastic Constants of Additive Manufactured and Wrought Ti6Al4V Alloys

by Ofer Tevet, David Svetlizky, David Harel, Zahava Barkay, Dolev Geva and Noam Eliaz

Materials 2022, 15(2), 638; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15020638 - 15 Jan 2022

Cited by 19 | Viewed by 2272

Abstract

Additively manufactured (AM) materials and hot rolled materials are typically orthotropic, and exhibit anisotropic elastic properties. This paper elucidates the anisotropic elastic properties (Young’s modulus, shear modulus, and Poisson’s ratio) of Ti6Al4V alloy in four different conditions: three AM (by selective laser melting, SLM, electron beam melting, EBM, and directed energy deposition, DED, processes) and one wrought alloy (for comparison). A specially designed polygon sample allowed measurement of 12 sound wave velocities (SWVs), employing the dynamic pulse-echo ultrasonic technique. In conjunction with the measured density values, these SWVs enabled deriving of the tensor of elastic constants (C_ij) and the three-dimensional (3D) Young’s moduli maps. Electron backscatter diffraction (EBSD) and micro-computed tomography (μCT) were employed to characterize the grain size and orientation as well as porosity and other defects which could explain the difference in the measured elastic constants of the four materials. All three types of AM materials showed only minor anisotropy. The wrought (hot rolled) alloy exhibited the highest density, virtually pore-free μCT images, and the highest ultrasonic anisotropy and polarity behavior. EBSD analysis revealed that a thin β-phase layer that formed along the elongated grain boundaries caused the ultrasonic polarity behavior. The finding that the elastic properties depend on the manufacturing process and on the angle relative to either the rolling direction or the AM build direction should be taken into account in the design of products. The data reported herein is valuable for materials selection and finite element analyses in mechanical design. The pulse-echo measurement procedure employed in this study may be further adapted and used for quality control of AM materials and parts. Full article

(This article belongs to the Special Issue Microstructure and Physical Properties of Additive Manufactured Alloys)

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11 pages, 3402 KiB

Open AccessEditor’s ChoiceArticle

Wear Behavior of a Heat-Treatable Al-3.5Cu-1.5Mg-1Si Alloy Manufactured by Selective Laser Melting

by Pei Wang, Yang Lei, Jun-Fang Qi, Si-Jie Yu, Rossitza Setchi, Ming-Wei Wu, Jürgen Eckert, Hai-Chao Li and Sergio Scudino

Materials 2021, 14(22), 7048; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14227048 - 20 Nov 2021

Cited by 7 | Viewed by 1746

Abstract

In this study, the wear behavior of a heat-treatable Al-7Si-0.5Mg-0.5Cu alloy fabricated by selective laser melting was investigated systematically. Compared with the commercial homogenized AA2024 alloy, the fine secondary phase of the SLM Al-Cu-Mg-Si alloy leads to a low specific wear rate (1.8 ± 0.11 × 10⁻⁴ mm³(Nm)⁻¹) and a low average coefficient of friction (0.40 ± 0.01). After the T6 heat treatment, the SLM Al-Cu-Mg-Si alloy exhibits a lower specific wear rate (1.48 ± 0.02 × 10⁻⁴ mm³(Nm)⁻¹), but a similar average coefficient of friction (0.34 ± 0.01) as the heat-treated AA2024 alloy. Altogether, the SLM Al-3.5Cu-1.5Mg-1Si alloy is suitable for the achievement of not only superior mechanical performance, but also improved tribological properties. Full article

(This article belongs to the Special Issue Microstructure and Physical Properties of Additive Manufactured Alloys)

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14 pages, 12013 KiB

Open AccessArticle

Directionally-Dependent Mechanical Properties of Ti6Al4V Manufactured by Electron Beam Melting (EBM) and Selective Laser Melting (SLM)

by Tim Pasang, Benny Tavlovich, Omri Yannay, Ben Jackson, Mike Fry, Yuan Tao, Celine Turangi, Jia-Chang Wang, Cho-Pei Jiang, Yuji Sato, Masahiro Tsukamoto and Wojciech Z. Misiolek

Materials 2021, 14(13), 3603; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14133603 - 28 Jun 2021

Cited by 22 | Viewed by 2902

Abstract

An investigation of mechanical properties of Ti6Al4V produced by additive manufacturing (AM) in the as-printed condition have been conducted and compared with wrought alloys. The AM samples were built by Selective Laser Melting (SLM) and Electron Beam Melting (EBM) in 0°, 45° and 90°—relative to horizontal direction. Similarly, the wrought samples were also cut and tested in the same directions relative to the plate rolling direction. The microstructures of the samples were significantly different on all samples. α′ martensite was observed on the SLM, acicular α on EBM and combination of both on the wrought alloy. EBM samples had higher surface roughness (Ra) compared with both SLM and wrought alloy. SLM samples were comparatively harder than wrought alloy and EBM. Tensile strength of the wrought alloy was higher in all directions except for 45°, where SLM samples showed higher strength than both EBM and wrought alloy on that direction. The ductility of the wrought alloy was consistently higher than both SLM and EBM indicated by clear necking feature on the wrought alloy samples. Dimples were observed on all fracture surfaces. Full article

(This article belongs to the Special Issue Microstructure and Physical Properties of Additive Manufactured Alloys)

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17 pages, 6211 KiB

Open AccessArticle

Tailoring Microstructure and Mechanical Properties of Additively-Manufactured Ti6Al4V Using Post Processing

by Yaron Itay Ganor, Eitan Tiferet, Sven C. Vogel, Donald W. Brown, Michael Chonin, Asaf Pesach, Amir Hajaj, Andrey Garkun, Shmuel Samuha, Roni Z. Shneck and Ori Yeheskel

Materials 2021, 14(3), 658; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14030658 - 31 Jan 2021

Cited by 27 | Viewed by 3532

Abstract

Additively-manufactured Ti-6Al-4V (Ti64) exhibits high strength but in some cases inferior elongation to those of conventionally manufactured materials. Post-processing of additively manufactured Ti64 components is investigated to modify the mechanical properties for specific applications while still utilizing the benefits of the additive manufacturing process. The mechanical properties and fatigue resistance of Ti64 samples made by electron beam melting were tested in the as-built state. Several heat treatments (up to 1000 °C) were performed to study their effect on the microstructure and mechanical properties. Phase content during heating was tested with high reliability by neutron diffraction at Los Alamos National Laboratory. Two different hot isostatic pressings (HIP) cycles were tested, one at low temperature (780 °C), the other is at the standard temperature (920 °C). The results show that lowering the HIP holding temperature retains the fine microstructure (~1% β phase) and the 0.2% proof stress of the as-built samples (1038 MPa), but gives rise to higher elongation (~14%) and better fatigue life. The material subjected to a higher HIP temperature had a coarser microstructure, more residual β phase (~2% difference), displayed slightly lower Vickers hardness (~15 HV_10N), 0.2% proof stress (~60 MPa) and ultimate stresses (~40 MPa) than the material HIP’ed at 780 °C, but had superior elongation (~6%) and fatigue resistance. Heat treatment at 1000 °C entirely altered the microstructure (~7% β phase), yield elongation of 13.7% but decrease the 0.2% proof-stress to 927 MPa. The results of the HIP at 780 °C imply it would be beneficial to lower the standard ASTM HIP temperature for Ti6Al4V additively manufactured by electron beam melting. Full article

(This article belongs to the Special Issue Microstructure and Physical Properties of Additive Manufactured Alloys)

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