A review on stress determination and control in metal-based additive manufacturing

Metal additive manufacturing(MAM)is an emerging and disruptive technology that builds three-dimensional(3D)components by adding layer-upon-layer of metallic materials.The complex cyclic thermal history and highly localized energy can produce large temperature gradients,which will,in turn,lead to compressive and tensile stress during the MAM process and eventually result in residual stress.Being an issue of great concern,residual stress,which can cause distortion,delamination,cracking,etc.,is considered a key mechanical quantity that affects the manufacturing quality and service performance of MAM parts.In this review paper,the ongoing work in the field of residual stress determination and control for MAM is described with a particular emphasis on the experimental measurement/control methods and numerical models.We also provide insight on what still requires to be achieved and the research opportunities and challenges.

Aspects of the Powder in Metal Additive Manufacturing: A Review

The most widely used metal additive manufacturing processes utilize powder that is spread or fed onto a building platform. Although there are reviews of the literature on some aspects of the powder, many aspects have been under-reviewed or unreviewed. The present work is a review of the literature on these aspects. Articles published in the open literature through the end of February 2022 were collected by consulting highly regarded relevant bibliographic databases, such as Google Scholar and Science Direct. The aspects reviewed were emerging methods of powder production, methods used to improve the quality of a powder after production by a well-established method, influence of variables of well-established powder production methods on powder properties, influence of powder production method on powder properties, and influence of powder reuse on properties of powders of a wide collection of alloys. One key finding was that with regard to powder reuse, the only consistent finding is that it leads to increase in the oxygen content of the powder. Another key finding was that the literature on the aspects of the literature reviewed herein contains many shortcomings and gaps, which suggest potential areas for future research, such as techniques for optimization of process variables for a given combination of metal powder and powder production method and development of methods for production of powders of new/emerging metallic materials.

A NOVEL SYNTHETIC METHOD AND STRUCTURE OF TETRAKIS(BENZOATE)BIS(TRIPHENYLPHOSPHINE OXIDE)DICOPPER(II).OXIDATIVE ADDITION OF DIBENZOYL ON METALLIC COPPER

Dibenzoyl peroxide undergoes oxidative addition on metallic copper with triphenylphosphine in a mixed solvent(acetone,dichloromethane and trichloromethane),and affords the binuclear copper complex (Cu(C_6H_5COO)_2(OPPh_3))_2.Crystals are monoclinic,space group A_2/a,with cell parameters,a=24.337(3),b=10.566(1),c=21.579(2),β= 93.18(1)°, V=5540(1)~3,Z=4,R=0.042,and Rw=0.044 for 5872 observed reflections. Each copper ion is coordinated by four bridging benzoato ligands and one triphenylphosphine oxide group to form binuclear complexes.

SYNTHESIS AND STRUCTURE OF Cu(Ⅱ)COMPLEXES BY OXIDATIVE ADDITION OF DIBENZOYL PEROXIDE ON METALLIC COPPER

Dibenzoyl peroxide undergoes oxidative addition on metallic copper powder with 2,2′-bipyridine(or imidazole)in a mixed solvent(methanol and tetrahydrofuran),and affords the Cu(Ⅱ)complexes-[Cu(Ce(C_6H_5COO)_2(2,2'-bipy)]H_2O(1) and[Cu(C_6H_5COO)_2(C_3H_4N_2)_2](2).The structure was solved by direct methods and Fourier synthesis.C_(24)H_(20)N_2O_5Cu (1),Mr=479.78,space group P2(1)/c,a=6.986(7), b=18.833(I),c=17.021(3),α=γ=90°,Z=4,V=2218.1~3,Dc=1.443g/cm\+3,R=0.055 Rw=0.062.Complex(2),C_(20)H_(18)N_4O_4Cu(2),Mr=441.74,space group P2(1)/n,a=8.699(4), b=9.840(6),c=12.399(5),α=γ=90°,β=100.8°,Z=4,V=1010.9~3,Dc=1.654g/cm\+3,R=0.055, Rw=0.062.

High plastic Zr–Cu–Fe–Al–Nb bulk metallic glasses for biomedical applications

Four Zr–Cu–Fe–Al-based bulk metallic glasses（BMGs） with Zr contents greater than 65at% and minor additions of Nb were designed and prepared. The glass forming abilities, thermal stabilities, mechanical properties, and corrosion resistance properties of the prepared BMGs were investigated. These BMGs exhibit moderate glass forming abilities along with superior fracture and yield strengths compared to previously reported Zr–Cu–Fe–Al BMGs. Specifically, the addition of Nb into this quaternary system remarkably increases the plastic strain to 27.5%, which is related to the high Poisson＇s ratio and low Young＇s and shear moduli. The Nb-bearing BMGs also exhibit a lower corrosion current density by about one order of magnitude and a wider passive region than 316 L steel in phosphate buffer solution（PBS, pH 7.4）. The combination of the optimized composition with high deformation ability, low Young＇s modulus, and excellent corrosion resistance properties indicates that this kind of BMG is promising for biomedical applications.

Review on Enhancement of Nitridation of Si Powder

This paper reviewed the effect of powder characteristics and additives including metals,rare earth oxides,and ZrO2 on nitridation of Si powder.The decrease of particle size of Si powder increased nitridation.Most of metal additives inhibited nitridation,while some metal additives such as Fe,Cu,Cr,and Ca increased nitrida—tion.Otherwise,the addition of metals might lead to the degradation of physical and mechanical properties of Si3N4.All the rare earth oxides,especially CeO2 and Eu2O3,showed nitridation enhancing effect.In addition,ZrO2 with small particle size showed a stronger enhancing effect.

Design of high-performance molybdenum alloys via doping metal oxide and carbide strengthening:A review

Metal oxide and carbide strengthening molybdenum(Mo)alloys have been designed as promising ad-vanced materials in refractory metals to solve some of the core engineering problems in superalloy ap-plications.Hence,there is a need to summarize the results obtained and evaluate the opportunities for preparing high-performance Mo alloys by strengthening metal oxides and carbides to improve the per-formance characteristics of Mo metal materials.This paper reviews the results of the reported work con-cerning the structure and properties of Mo alloys with different metal oxide and carbide strengthening methods added to Mo matrix.The influence of the doping of La 2 O 3 and Y 2 O 3 particles,ceramic Al 2 O 3 and ZrO 2 particles,and refractory TiC and ZrC carbides particles of Mo alloys are discussed.The impacts of particle morphology,size,distribution and volume fractions of oxide and carbide are analyzed,as well as the specific features of different doping techniques for obtaining high-performance Mo alloys mate-rials.This work will guide future research on the design of high-performance refractory Mo alloys by adding oxides and carbide particles,helping to solve the core issues in the field of superalloy application research.

Numerical simulation of laser ultrasonic detection of the surface microdefects on laser powder bed fusion additive manufactured 316L stainless steel

A numerical model is presented in this article to investigate the interactions between laser generated ultrasonic and the microdefects(0.01 to 0.1 mm),which are on the surface of the laser powder bed fusion additive manufactured 316L stainless steel.Firstly,the influence of the transient sound field and detection positions on Rayleigh wave signals are investigated.The interactions between the varied microdefects and the laser ultrasonic are studied.It is shown that arrival time of reflected Rayleigh(RR)waves wave is only related to the location of defects.The depth can be checked from the feature point Q,the displacement amplitude and time delay of converted transverse(RS)wave,while the width information can be evaluated from the RS wave time delay.With the aid of fitting curves,it is found to be linearly related.This simulation study provides a theoretical basis for quantitative detection of surface microdefects of additive manufactured 316L stainless steel components.

Multi-scale defects in powder-based additively manufactured metals and alloys

Defect formation is a critical challenge for powder-based metal additive manufacturing(AM).Current understanding on the three important issues including formation mechanism,influence and control method of metal AM defects should be updated.In this review paper,multi-scale defects in AMed metals and alloys are identified and for the first time classified into three categories,including geometry related,surface integrity related and microstructural defects.In particular,the microstructural defects are further divided into internal cracks and pores,textured columnar grains,compositional defects and dislocation cells.The root causes of the multi-scale defects are discussed.The key factors that affect the defect formation are identified and analyzed.The detection methods and modeling of the multi-scale defects are briefly introduced.The effects of the multi-scale defects on the mechanical properties especially for tensile properties and fatigue performance of AMed metallic components are reviewed.Various control and mitigation methods for the corresponding defects,include process parameter control,post processing,alloy design and hybrid AM techniques,are summarized and discussed.From research aspect,current research gaps and future prospects from three important aspects of the multi-scale AM defects are identified and delineated.

Effect of yttrium addition on flow behavior of Cu-Zr-Al bulk metallic glass in the supercooled liquid region

The high temperature deformation behaviors and thermal workability of Cu_（43）Zr_（48）Al_9 and（Cu_（43）Zr_（48）Al_9）_（98）Y_2 bulk metallic glasses in the supercooled liquid region were investigated by the uniaxial compression tests. The results showed that the high temperature deformation behaviors were highly sensitive to strain rate and temperature, and the flow stress decreased with the increase of temperature, as well as with the decrease of strain rate. Additionally, the（Cu_（43）Zr_（48）Al_9）_（98）Y_2 bulk metallic glass displayed smaller flow stress under the same condition. The flow behavior changed from Newtonian to non-Newtonian with increase of the strain rate, as well as the decrease of temperature, which could be explained by the transition state theory. We found that（Cu_（43）Zr_（48）Al_9）_（98）Y_2 bulk metallic glass had better flow behavior than the Cu_（43）Zr_（48）Al_9 bulk metallic glass in the supercooled liquid region. In addition, the processing maps of the two bulk metallic glasses were constructed considering the power dissipation efficiency. The optimum domain for thermal workability of the bulk metallic glass was located using the processing map, where the power dissipation efficiency was larger than 0.8. It was shown that the（Cu_（43）Zr_（48）Al_9）_（98）Y_2 bulk metallic glass, which had larger area of optimum domain, had excellent thermoplastic forming.