MECH 991- Pierson Graduate Seminar, Fall 2017

Report on: Metals for Additive Manufacturing

Presenter: Dr. David L. Bourell
Date of Presentation: October 3, 2017
Report by: Md Rashidul Hasib
Advisor: Dr. K. P. Rajurkar

ABSTRACT

Additive Manufacturing (AM) - the industrial version of 3-D printing has seen exponential growth
in recent years. While 3-D printing for consumers and small entrepreneurs has received a great
deal of publicity, it is in manufacturing where the technology will have its most
significant commercial impact. The presentation starts with the development of
metal additive manufacturing and provides a glimpse of the current state of the art in
terms of process development and properties of the parts produced. Then it focuses on
the use of elemental powder feedstock in AM to manufacture crack-free metallic parts in
otherwise difficult-to-process metal alloys.

DESCRIPTION OF THE WORK

Guidelines for Metal AM For non-fusion AM processes (binder jetting, sheet

lamination), the main factor is producing the feedstock in proper form. For fusion AM
processes (powder bed fusion, directed energy deposition), metals that weld well
and cast well typically are processable by AM [e.g. Ti-6Al-4V, 316L stainless steel, AlSi10Mg].

Material Related Challenges for Metal AM The main obstacles are affinity for
atmosphere constituents, high reflectivity and thermal conductivity, residual stress.

Microstructural Anisotropy There can be columnar microstructures in SLM of

Ti6Al4V. Visible melt pools have also been detected in SLM of 316L. These
melt pools when etched reveal significant epitaxial grain structure across melt layers.
Balling phenomenon characterized by highly coarsened balls possessing an interrupted
dendritic structure in the surface layer of balls has also been observed. Porosity from lack
of melting or gas is also a common defect.
AM Materials Properties: Stiffness, strength, hardness is roughly as equal as conventional
processing. But there is a general trade off between strength and ductility. Heat treatment
generally leads to reduction of strength and increase in ductility. AM parts tend to have less
ductility, fatigue life, toughness. Ductility decreases with the increase in porosity. There is a
decrease in fatigue life of additively manufactured parts. Though it can be improved
with heat treatment and surface machining.

Outlook for Materials in AM Additive manufacturing can give us novel and effective approach
for tailoring alloys and microstructure. We can manufacture functionally gradient materials.
Different elemental blends can be used for alloy development matrices, customizing specific
alloys or facilitating processing. Heat treatment of AM parts can reduce melt pools, give more
equiaxed grains which are common in this process. A material database for AM materials can
assist users to choose the right material and process. Additive Manufacturability Index, a
measure of success with which a material may be additively manufactured is also needed.

SUMMARY AND CONCLUSIONS

Additive Manufacturing is growing at a high rate internationally. Feedstock for AM must be

formed to manufacturable shape, and provide acceptable service properties. Metal AM part
properties are improving toward cast and wrought properties and common defects have been
identified and must be controlled. Future trends in AM of materials include: Tailoring alloys and
microstructure, creation of AM materials databases, AM manufacturability indexing.