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A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties

H.R. Kotadia, G. Gibbons, Amit Das Orcid Logo, P.D. Howes

Additive Manufacturing, Volume: 46, Start page: 102155

Swansea University Author: Amit Das Orcid Logo

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Abstract

Additive manufacturing (AM) of metallic alloys for structural and functional applications has attracted significant interest in the last two decades as it brings a step change in the philosophy of design and manufacturing. The ability to design and fabricate complex geometries not amenable to conven...

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Published in: Additive Manufacturing
ISSN: 2214-8604
Published: Elsevier BV 2021
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URI: https://cronfa.swan.ac.uk/Record/cronfa57325
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spelling 2021-08-03T13:22:59.6460485 v2 57325 2021-07-15 A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties 4d785df766daed9a857c934bb130ed8b 0000-0002-7196-6254 Amit Das Amit Das true false 2021-07-15 MTLS Additive manufacturing (AM) of metallic alloys for structural and functional applications has attracted significant interest in the last two decades as it brings a step change in the philosophy of design and manufacturing. The ability to design and fabricate complex geometries not amenable to conventional manufacturing, and the potential to reduce component weight without compromising performance, is particularly attractive for aerospace and automotive applications. This has culminated in rapid progress in AM with Ti- and Ni-based alloys. In contrast, the development of AM with Al-alloys has been slow, despite their widespread adoption in industry owing to an excellent combination of low density and high strength-to-weight ratio. Research to date has focused on castable and weldable AlSiMg-based alloys (which are less desirable for demanding structural applications), as well as on the development of new AM-specific AlMgSc alloys (based on 5xxx series). However, high strength wrought Al-alloys have typically been unsuitable for AM due to their unfavourable microstructural characteristics under rapid directional solidification conditions. Nevertheless, recent research has shown that there is promise in overcoming the associated challenges. Herein, we present a review of the current status of AM with Al-alloys. We primarily focus on the microstructural characteristics, and on exploring how these influence mechanical properties. The current metallurgical understanding of microstructure and defect formation in Al-alloys during AM is discussed, along with recent promising research exploring various microstructural modification methodologies. Finally, the remaining challenges in the development of AM with high-strength Al-alloys are discussed. Journal Article Additive Manufacturing 46 102155 Elsevier BV 2214-8604 Aluminium, Additive Manufacturing, Powder Bed Fusion (PBF), Solidification, Microstructure, Mechanical properties 1 10 2021 2021-10-01 10.1016/j.addma.2021.102155 COLLEGE NANME Materials Science and Engineering COLLEGE CODE MTLS Swansea University 2021-08-03T13:22:59.6460485 2021-07-15T09:45:48.9884805 College of Engineering Engineering H.R. Kotadia 1 G. Gibbons 2 Amit Das 0000-0002-7196-6254 3 P.D. Howes 4 Under embargo Under embargo 2021-07-15T13:35:25.2147671 Output 3222293 application/pdf Accepted Manuscript true 2022-07-13T00:00:00.0000000 Released under the terms of a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International (CC BY-NC-ND 4.0) License true eng http://creativecommons.org/licenses/by-nc-nd/4.0/
title A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties
spellingShingle A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties
Amit Das
title_short A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties
title_full A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties
title_fullStr A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties
title_full_unstemmed A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties
title_sort A review of Laser Powder Bed Fusion Additive Manufacturing of aluminium alloys: Microstructure and properties
author_id_str_mv 4d785df766daed9a857c934bb130ed8b
author_id_fullname_str_mv 4d785df766daed9a857c934bb130ed8b_***_Amit Das
author Amit Das
author2 H.R. Kotadia
G. Gibbons
Amit Das
P.D. Howes
format Journal article
container_title Additive Manufacturing
container_volume 46
container_start_page 102155
publishDate 2021
institution Swansea University
issn 2214-8604
doi_str_mv 10.1016/j.addma.2021.102155
publisher Elsevier BV
college_str College of Engineering
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hierarchy_top_title College of Engineering
hierarchy_parent_id collegeofengineering
hierarchy_parent_title College of Engineering
department_str Engineering{{{_:::_}}}College of Engineering{{{_:::_}}}Engineering
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description Additive manufacturing (AM) of metallic alloys for structural and functional applications has attracted significant interest in the last two decades as it brings a step change in the philosophy of design and manufacturing. The ability to design and fabricate complex geometries not amenable to conventional manufacturing, and the potential to reduce component weight without compromising performance, is particularly attractive for aerospace and automotive applications. This has culminated in rapid progress in AM with Ti- and Ni-based alloys. In contrast, the development of AM with Al-alloys has been slow, despite their widespread adoption in industry owing to an excellent combination of low density and high strength-to-weight ratio. Research to date has focused on castable and weldable AlSiMg-based alloys (which are less desirable for demanding structural applications), as well as on the development of new AM-specific AlMgSc alloys (based on 5xxx series). However, high strength wrought Al-alloys have typically been unsuitable for AM due to their unfavourable microstructural characteristics under rapid directional solidification conditions. Nevertheless, recent research has shown that there is promise in overcoming the associated challenges. Herein, we present a review of the current status of AM with Al-alloys. We primarily focus on the microstructural characteristics, and on exploring how these influence mechanical properties. The current metallurgical understanding of microstructure and defect formation in Al-alloys during AM is discussed, along with recent promising research exploring various microstructural modification methodologies. Finally, the remaining challenges in the development of AM with high-strength Al-alloys are discussed.
published_date 2021-10-01T04:13:24Z
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