Monitoring, Modeling, and Statistical Analysis in Metal Additive Manufacturing: A Review.

Despite the significant advances made involving the additive manufacturing (AM) of metals, including those related to both materials and processes, challenges remain in regard to the rapid qualification and insertion of such materials into applications. In general, understanding the process-microstructure-property interrelationships is essential. To successfully understand these interrelationships on a process-by-process basis and exploit such knowledge in practice, leveraging monitoring, modeling, and statistical analysis is necessary.

The Effect of Interlayer Delay on the Heat Accumulation, Microstructures, and Properties in Laser Hot Wire Directed Energy Deposition of Ti-6Al-4V Single-Wall.

Laser hot wire directed energy deposition (LHW-DED) is a layer-by-layer additive manufacturing technique that permits the fabrication of large-scale Ti-6Al-4V (Ti64) components with a high deposition rate and has gained traction in the aerospace sector in recent years. However, one of the major challenges in LHW-DED Ti64 is heat accumulation, which affects the part quality, microstructure, and properties of as-built specimens. These issues require a comprehensive understanding of the layerwise heat-accumulation-driven process-structure-property relationship in as-deposited samples.

Understanding the Effect of Electron Beam Melting Scanning Strategies on the Aluminum Content and Materials State of Single Ti-6Al-4V Feedstock.

Research on the additive manufacturing of metals often neglects any characterization of the composition of final parts, erroneously assuming a compositional homogeneity that matches the feedstock material. Here, the composition of electron-beam-melted Ti-6Al-4V produced through three distinct scanning strategies (linear raster and two point melting strategies, random fill and Dehoff fill) is characterized both locally and globally through energy-dispersive spectroscopy and quantitative chemical analysis. As a result of the different scanning strategies used, differing levels of preferential vaporization occur across the various parts, leading to distinct final compositions, with extremes of ~5.

Evaluation of Ti-Mn Alloys for Additive Manufacturing Using High-Throughput Experimental Assays and Gaussian Process Regression.

Compositionally graded cylinders of Ti-Mn alloys were produced using the Laser Engineered Net Shaping (LENS™) technique, with Mn content varying from 0 to 12 wt.% along the cylinder axis. The cylinders were subjected to different post-build heat treatments to produce a large sample library of a-b microstructures.