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Differences in microstructure and properties between selective laser melting and traditional manufacturing

Bo SONG,Xiao ZHAO,Shuai LI,Changjun HAN,Qingsong WEI,Shifeng WEN,Jie LIU,Yusheng SHI

《机械工程前沿（英文）》 2015年 第10卷 第2期   页码 111-125 doi: 10.1007/s11465-015-0341-2

摘要：

Selective laser melting (SLM), as one of the additive manufacturing technologies, is widely investigated to fabricate metal parts. In SLM, parts are manufactured directly from powders in a layer-by-layer fashion; SLM also provides several advantages, such as production of complex parts with high three-dimensional accuracy, compared with other additive manufacturing technologies. Therefore, SLM can be applied in aeronautics, astronautics, medicine, and die and mould industry. However, this technique differs from traditional methods, such as casting and forging; for instance, the former greatly differs in terms of microstructure and properties of products. This paper summarizes relevant studies on metal material fabrication through SLM. Based on a work completed in Huazhong Univ. Sci Tech., Rapid Manuf. Center (HUST-RMC) and compared with characteristics described in other reported studies, microstructure, properties, dimensional accuracy, and application of SLM are presented.

关键词： selective laser melting     microstructure     performance     application    

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Build orientation determination of multi-feature mechanical parts in selective laser melting via multi-objective

《机械工程前沿（英文）》 2023年 第18卷 第2期 doi: 10.1007/s11465-022-0737-8

摘要： Selective laser melting (SLM) is a unique additive manufacturing (AM) category that can be used to manufacture mechanical parts. It has been widely used in aerospace and automotive using metal or alloy powder. The build orientation is crucial in AM because it affects the as-built part, including its part accuracy, surface roughness, support structure, and build time and cost. A mechanical part is usually composed of multiple surface features. The surface features carry the production and design knowledge, which can be utilized in SLM fabrication. This study proposes a method to determine the build orientation of multi-feature mechanical parts (MFMPs) in SLM. First, the surface features of an MFMP are recognized and grouped for formulating the particular optimization objectives. Second, the estimation models of involved optimization objectives are established, and a set of alternative build orientations (ABOs) is further obtained by many-objective optimization. Lastly, a multi-objective decision making method integrated by the technique for order of preference by similarity to the ideal solution and cosine similarity measure is presented to select an optimal build orientation from those ABOs. The weights of the feature groups and considered objectives are achieved by a fuzzy analytical hierarchy process. Two case studies are reported to validate the proposed method with numerical results, and the effectiveness comparison is presented. Physical manufacturing is conducted to prove the performance of the proposed method. The measured average sampling surface roughness of the most crucial feature of the bracket in the original orientation and the orientations obtained by the weighted sum model and the proposed method are 15.82, 10.84, and 10.62 μm, respectively. The numerical and physical validation results demonstrate that the proposed method is desirable to determine the build orientations of MFMPs with competitive results in SLM.

关键词： selective laser melting (SLM)     build orientation determination     multi-feature mechanical part (MFMP)     fuzzy analytical hierarchy process     multi-objective decision making (MODM)    

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选区激光熔化纯钨——粉末粒径对激光吸收的影响和扫描轨迹形成机理研究 Article

章佳窈, 顾冬冬, 杨莹, 张红梅, 陈洪宇, 戴冬华, 林开杰

《工程（英文）》 2019年 第5卷 第4期   页码 736-745 doi: 10.1016/j.eng.2019.07.003

摘要：

本文建立了基于线迹追踪的三维激光吸收模型，用于描述选区激光熔化（SLM）成形纯钨粉末时激光束与粉末层的相互作用，研究了粉末粒径大小对粉末激光吸收率和吸收行为的影响。本文给出了激光吸收率、粉层吸收辐照度及其分布、激光扫描轨迹的表面形貌和几何特征（如接触角、宽度和高度，以及重熔深度）之间的内在关系。模拟结果表明，粉末层的吸收率大大超过单一的粉末颗粒或致密平板材料的吸收率。随着粉末粒径增加，粉末层吸收的激光能量减少。当粒径为5 μm时，纯钨粉末层的吸收率最大达到0.6030。激光辐照度在粉床颗粒表面的分布与粒径大小、方位角和粉末在基板上的位置有关。当粒径从5 μm增加到45 μm时，粉末层中的最大辐照度从1.117 × 10–3 W·μm–2降低到0.85 × 10–3 W·μm–2，并且位于中心辐照区域的辐照度分布轮廓逐渐收缩。对SLM纯钨扫描轨迹的表面形貌和横截面几何特征进行了研究，结果验证了模拟的粉末激光吸收行为。该工作对线迹追踪模型预测SLM扫描轨迹润湿性和铺展性的应用提供了科学依据，从而更好地获得优异的激光成形性能。

关键词： 选区激光熔化     钨     线迹追踪模型     吸收率     激光扫描轨迹    

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微观选择性激光熔化技术发展的现状及未来展望 Review

Balasubramanian Nagarajan, Zhiheng Hu, Xu Song, Wei Zhai, Jun Wei

《工程（英文）》 2019年 第5卷 第4期   页码 702-720 doi: 10.1016/j.eng.2019.07.002

摘要：

增材制造（AM）能将各种材料制成形状复杂的部件，因此在制造业中越来越受到青睐。选择性激光熔化（SLM）是一种常见的AM技术，它基于粉床熔融法（PBF）来处理金属，但目前只专注于大中型元件的制作。本文综述了微型金属材料SLM的研究现状。与通常用于微观AM的直接写入技术相比，微观SLM由于许多因素而更加具有吸引力，包括更快的周期时间、流程简单性和材料通用性。此外，本文综合评价了利用SLM和选择性激光烧结（SLS）制造微尺度零件的各种研究工作和商业系统，不仅从微观尺度上找出了SLM存在的问题，包括粉末重涂、激光光学和粉末粒度等， 还详细阐述了SLM未来的发展方向。文章详细回顾了粉床技术中现有的粉末重涂方法，并描述了在AM领域实施干粉分配方法的新进展。对AM部件的一些二次整理技术进行了回顾，重点介绍了细微加工特征的应用以及与微观SLM系统的结合。

关键词： 增材制造     选择性激光熔化     微细加工     混合处理     粉床重涂    

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结构参数对激光熔化制造的2D五模结构泊松比和压缩模量的影响 Article

张磊, 宋波, 刘瑞杰, 赵爱国, 张金良, 卓林蓉, 汤桂平, 史玉升

《工程（英文）》 2020年 第6卷 第1期   页码 56-67 doi: 10.1016/j.eng.2019.06.009

摘要： 为了验证模拟的力学性能结果，采用选择性激光熔化（selective laser melting, SLM）方法制备了Ti-6Al-4V合金的五模结构试样，并对其力学性能（泊松比和弹性模量）进行了实验研究

关键词： 超材料     五模材料     有限元分析     激光选区熔化    

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Review of materials used in laser-aided additive manufacturing processes to produce metallic products

Xiaodong NIU, Surinder SINGH, Akhil GARG, Harpreet SINGH, Biranchi PANDA, Xiongbin PENG, Qiujuan ZHANG

《机械工程前沿（英文）》 2019年 第14卷 第3期   页码 282-298 doi: 10.1007/s11465-019-0526-1

摘要： Rapid prototyping (RP) or layered manufacturing (LM) technologies have been extensively used to manufacture prototypes composed mainly of plastics, polymers, paper, and wax due to the short product development time and low costs of these technologies. However, such technologies, with the exception of selective laser melting and sintering, are not used to fabricate metallic products because of the resulting poor life, short cycle, poor surface finish, and low structural integrity of the fabricated parts. The properties endowed by these parts do not match those of functional parts. Therefore, extensive research has been conducted to develop new additive manufacturing (AM) technologies by extending existing RP technologies. Several AM technologies have been developed for the fabrication of metallic objects. These technologies utilize materials, such as Ni-, Al-, and Ti-based alloys and stainless steel powders, to fabricate high-quality functional components. The present work reviews the type of materials used in laser-based AM processes for the manufacture of metallic products. The advantages and disadvantages of processes and different materials are summarized, and future research directions are discussed in the final section. This review can help experts select the ideal type of process or technology for the manufacturing of elements composed of a given alloy or material (Ni, Ti, Al, Pb, and stainless steel).

关键词： direct metal deposition     laser-based manufacturing     rapid manufacturing     selective laser melting     additive manufacturing    

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Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite

Omotoyosi H. FAMODIMU, Mark STANFORD, Chike F. ODUOZA, Lijuan ZHANG

《机械工程前沿（英文）》 2018年 第13卷 第4期   页码 520-527 doi: 10.1007/s11465-018-0521-y

摘要：

Laser melting of aluminium alloy—AlSi10Mg has increasingly been used to create specialised products in various industrial applications, however, research on utilising laser melting of aluminium matrix composites in replacing specialised parts have been slow on the uptake. This has been attributed to the complexity of the laser melting process, metal/ceramic feedstock for the process and the reaction of the feedstock material to the laser. Thus, an understanding of the process, material microstructure and mechanical properties is important for its adoption as a manufacturing route of aluminium metal matrix composites. The effects of several parameters of the laser melting process on the mechanical blended composite were thus investigated in this research. This included single track formations of the matrix alloy and the composite alloyed with 5% and 10% respectively for their reaction to laser melting and the fabrication of density blocks to investigate the relative density and porosity over different scan speeds. The results from these experiments were utilised in determining a process window in fabricating near-fully dense parts.

关键词： selective laser melting     additive manufacturing     mechanical alloying     powder metallurgy     aluminium metal matrix composite    

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变环境压力下的激光选区熔化——介观尺度模型与输运现象 Article

胡仁志, 罗曼乐兰, 黄安国, 吴甲民, 魏青松, 文世峰, 张李超, 史玉升, Dmitry Trushnikov, V. Ya. Belenkiy, I. Yu. Letyagin, K.P. Karunakaran, 庞盛永

《工程（英文）》 2021年 第7卷 第8期   页码 1157-1164 doi: 10.1016/j.eng.2021.07.003

摘要：

近期研究表明，相比常压条件下，采用真空或低压环境的激光选区熔化（SLM）工艺可获得缺陷更少、表面质量更优的打印件。虽然通过高速摄像实验已经对SLM工艺在真空环境下的介观物理过程进行了部分研究，但该工艺下影响熔池传热和流动方面的深层机理仍不十分清楚。为此，基于最近的激光焊接模型工作，我们首次建立了变环境压力下SLM工艺的介观尺度数学模型。我们模拟了大气压和100 Pa低压环境下SLM工艺中316L粉末的输运现象。研究发现，在典型工艺参数（激光功率：200 W；扫描速度：2 ms-1；粉末直径：27 µm）下，大气环境中熔池表面凹坑的平均温度将近2800 K，而在100 Pa环境压力时，平均温度仅为2300 K。由于在100 Pa低压条件下，蒸发引起的表面压力和环境压力之间的压差相对于大气环境下的压差更大，更易驱动高温流体流动，因此熔池表面流动速度更加剧烈（平均速度约为4 m·s-1）。研究表明，熔池表面周期性的波浪流动（周期：14 µs）直接影响堆积体的表面粗糙度。此外，由于雷诺数小于400且远低于湍流临界值，熔融金属液流动模式为层流，因此，黏性耗散的影响至关重要。在真空或低环境压力条件下，波纹的流动轨迹更长，使得波动更容易由于黏性效应被耗散，从而改善了打印件的表面粗造度。总之，我们的数学模型阐明了变环境压力下SLM工艺实验研究中观察到的有趣输运现象的物理机制，它有望成为优化SLM工艺过程的有力工具。

关键词： 激光选区熔化     介观尺度模型     环境压力     输运现象    

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用于介观模拟电子束选区熔化的数据挖掘技术 Article

钱亚, 闫文韬, 林峰

《工程（英文）》 2019年 第5卷 第4期   页码 746-754 doi: 10.1016/j.eng.2019.06.006

摘要：

 在电子束选区熔化技术（EBSM）工艺中，制造部件的性质受到每一道熔道沉积质量的影响。然而，熔道的形成受到各种物理现象和工艺参数的支配，这些参数之间的相关性十分复杂，难以通过实验得出。近来，介观建模技术已成为模拟电子束（EB）熔化过程以及揭示特定熔道形貌的形成机制的手段。尽管如此，人们对工艺参数与熔道特征之间的相关性尚未有定量的理解。本文从介观模拟的结果出发，研究了熔道的形态特征，同时引入了熔道宽度和高度等关键性描述指标，以便从数值上评估沉积质量。本文还定量研究了各种工艺参数的影响，从而导出了工艺条件和熔道特征之间的相关性。最后，本文提出了一种由介观建模和数据挖掘技术组成的仿真驱动优化框架，并讨论了框架的潜力和局限性。

关键词： 电子束选区熔化     介观模型     数据挖掘    

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激光增材制造的热力学和动力学多尺度理解

顾冬冬, 马成龙, 夏木建, 戴冬华, 石齐民

《工程（英文）》 2017年 第3卷 第5期   页码 675-684 doi: 10.1016/J.ENG.2017.05.011

摘要：

选择性激光熔化（SLM）增材制造（AM）技术已成为精密制造高性能复杂形状金属零件的重要选择。SLM AM 工艺涉及复杂的物理化学现象、热力学特性以及高能激光束融化散粉颗粒时产生的相变。本文提出了针对金属材料SLM 工艺的多尺度建模和协调控制，其中，金属材料包括铝（Al）基合金（AlSi10Mg）、镍（Ni）基超合金（Inconel 718）及陶瓷颗粒增强的铝基和镍基复合材料。从微观尺度研究氮化铝（AlN）颗粒在SLM 处理后的铝基纳米复合材料中的迁移和分布机制以及SLM处理后的碳化钨（WC）/Inconel 718 复合材料中增强体和基体之间梯度界面的原位形成。从中尺度研究AlSi10Mg 和Inconel 718 合金粉末的激光吸收和熔化/ 致密化特性。最后，从宏观尺度提出了逐行局部激光扫描过程中的应力发展和SLM 处理后的复合材料变形的参数依赖控制方法。多尺度数值模拟和实验验证方法有利于监测SLM AM 过程中复杂的粉末激光作用、传热传质特性以及微观结构和力学性能的发展。

关键词： 增材制造     选择性激光熔化     多尺度建模     热力学     动力学    

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双金属电子束选区熔化的硬件开发与成形实验 Article

郭超, 葛文君, 林峰

《工程（英文）》 2015年 第1卷 第1期   页码 124-130 doi: 10.15302/J-ENG-2015013

摘要：

电子束选区熔化（EBSM）是一种利用电子束扫描、熔化金属粉末逐层制造三维实体零件的增材制造技术。近年来，EBSM已经成功应用于多种材料的增材制造。现有EBSM工艺方面的研究主要聚焦于单种材料的成形，本研究提出一种能够利用两种粉末材料成形梯度结构的EBSM工艺，提出基于振动的粉末供给方法，并实现了两种粉末材料独立供给并混合。利用Ti6Al4V和Ti47Al2Cr2Nb两种材料进行成形。Ti6Al4V在室温下有很好的强度与塑性，而Ti47Al2Cr2Nb在高温下性能优良，但有很大的室温脆性。本研究提出的双金属EBSM工艺成功制备了Ti6Al4V/Ti47Al2Cr2Nb梯度结构，并利用光学显微镜、扫描电子显微镜、电子微探针分析等方法研究了该梯度结构的微观组织和化学成分。结果显示，梯度结构的截面厚度约为300 μm，没有裂纹，化学成分在界面处呈阶梯式变化。

关键词： 增材制造     电子束     选区熔化     梯度材料     钛合金     钛铝合金    

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Erratum to ‘‘Modeling and Experimental Validation of the Electron Beam Selective Melting Erratum

Wentao Yan, Ya Qian, Weixin Ma, Bin Zhou, Yongxing Shen, Feng Lin

《工程（英文）》 2018年 第4卷 第1期   页码 164-164 doi: 10.1016/j.eng.2017.12.012

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Two-dimensional modeling of sintering of a powder layer on top of nonporous substrate

Tiebing CHEN, Yuwen ZHANG,

《机械工程前沿（英文）》 2010年 第5卷 第2期   页码 143-148 doi: 10.1007/s11465-010-0006-0

摘要： Selective laser sintering (SLS) of a two-component metal powder layer on the top of multiple sintered layers by a moving Gaussian laser beam is modeled. The loose metal powder layer is composed of a powder mixture with significantly different melting points. The physical model that accounts the shrinkage induced by melting is described by using a temperature-transforming model. The effects of the porosity and the thickness of the atop loose powder layer with different numbers of the existing sintered metal powder layers below on the sintering process are numerically investigated. The present work will provide a better understanding to simulate much more complicated three-dimensional SLS process.

关键词： laser     sintering     melting     solidification     heat transfer    

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Ultrafast solid-liquid-vapor phase change of a thin gold film irradiated by femtosecond laser pulses

Jing HUANG, Yuwen ZHANG, J. K. CHEN, Mo YANG

《能源前沿（英文）》 2012年 第6卷 第1期   页码 1-11 doi: 10.1007/s11708-012-0179-9

摘要： Effects of different parameters on the melting, vaporization and resolidification processes of thin gold film irradiated by femtosecond pulses and pulse train were systematically studied. The classical two-temperature model was adopted to depict the non-equilibrium heat transfer in electrons and lattice. The melting and resolidification processes, which was characterized by the solid-liquid interfacial velocity, as well as elevated melting temperature and depressed solidification temperature, was obtained by considering the interfacial energy balance and nucleation dynamics. Vaporization process which leads to ablation was described by tracking the location of liquid-vapor interface with an iterative procedure based on energy balance and gas kinetics law. The parameters in discussion included film thickness, laser fluence, pulse duration, pulse number, repetition rate, pulse train number, etc. Their effects on the maximum lattice temperature, melting depth and ablation depth were discussed based on the simulation results.

关键词： melting     evaporation     nucleation dynamics     nanoscale heat transfer    

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增材制造可降解镁合金植入物面临的挑战及其对策 Article

王银川, 付彭怀, 王南清, 彭立明, 康斌, 曾晖, 袁广银, 丁文江

《工程（英文）》 2020年 第6卷 第11期   页码 1267-1275 doi: 10.1016/j.eng.2020.02.015

摘要：

增材制造（AM）技术具有制备复杂几何结构的能力，为可降解金属植入物的制备提供了前所未有的机会，尤其对具有合适力学性能和良好生物相容性的可降解镁合金。然而，AM可降解镁基植入物面临着许多挑战，如镁粉制备困难以及AM过程中的粉体飞溅和裂纹形成。本文分析了AM可降解镁合金所面临的挑战，并提出了相应的应对策略，成功制备了一种表面光滑且圆整度好的新型镁合金（JDBM）粉体，然后对其AM参数进行了优化。在优化参数的基础上，采用选区激光熔化（SLM）技术制备了三种不同结构（仿生、金刚石和极小曲面）的JDBM多孔支架，并分析了其力学性能和降解行为。最后，筛选出性能最优的极小曲面支架进行透钙磷石（DCPD）涂层处理，该涂层极大地抑制了支架降解速率，并提高了其细胞相容性。AM镁合金支架展现了作为骨组织工程支架的临床应用前景。

关键词： 增材制造     选区激光熔化     可降解镁合金     组织工程支架     表面改性    

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