Review
Engineering, Manufacturing
Yongjian Fang, Min-Kyeom Kim, Yali Zhang, Ziyang Duan, Quan Yuan, Jonghwan Suhr
Summary: This paper systematically reviews the design, manufacturing, and analysis process of selective laser melting (SLM) of particulate-reinforced iron-based metal matrix composites (MMCs). It discusses the design and preparation of powder mixture, SLM process design, post-processing and post-treatment, as well as metallurgical behaviors, defects, properties, and strengthening mechanisms of MMCs. Particularly, it provides detailed discussions on the selection and design of layer thickness, laser power, scanning speed, hatch spacing, scanning strategy, chamber atmosphere, and pre-heating.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Chemistry, Physical
Q. Yan, B. Chen, J. S. Li
Summary: In this study, graphene nanosheet (GNS)-reinforced Ti-6Al-4V matrix composite was successfully fabricated using selective laser melting (SLM) process, which exhibited super-high tensile strength and high Young's modulus. The locally reacted GNSs and in-situ formed ultrafine TiC particles were found to be the main contributors to the outstanding mechanical properties of the composite.
Article
Chemistry, Physical
Vijay Mandal, Pragya Tripathi, Ashwani Kumar, Sudhanshu S. Singh, J. Ramkumar
Summary: In this study, TiC and B4C reinforced Inconel 718 metal matrix composites were fabricated using selective laser melting. Good interfacial bonding was observed for TiC/IN718 composites, while micro-cracks were found in B4C/IN718 composites. Thermal modeling predicted higher stresses at the interfaces. The defects and mechanisms in the composites were analyzed using SEM and XRT. Decreasing scanning speed reduced fusion and balling defects but increased keyhole porosity. Increasing scanning speed and TiC content decreased and increased the micro-hardness of the composites, respectively. The IN718-30% TiC composite exhibited the highest hardness and wear resistance.
JOURNAL OF ALLOYS AND COMPOUNDS
(2022)
Article
Materials Science, Multidisciplinary
Yang Jin, Xiaolong Zhao, Peikang Bai, Wenbo Du, Haihong Liao, Yuxin Li, Minjie Liang, Bing Han, Zhanyong Zhao, Kai Yang
Summary: Graphene/AlSi10Mg composites were fabricated using selective laser melting. Analysis of the microstructure showed that graphene was uniformly dispersed and reduced the cell size and nano-Si precipitates. The addition of graphene inhibited cell boundary movement and increased the cell nucleation rate, resulting in decreased size of the composite's cell and nano-Si precipitates.
Article
Materials Science, Multidisciplinary
Anthony DeMartino, Troy Y. Ansell, Andy Nieto
Summary: Carbon nanotubes are being studied as a leading-edge reinforcement for metal matrix composites, showing remarkable mechanical properties such as strength and elastic modulus. Utilizing selective laser melting, advanced metal matrix composites, such as Ti-6Al-4V, can be manufactured with enhanced microhardness and density, providing promising avenues for meeting the demands of the 21st century.
ADVANCED ENGINEERING MATERIALS
(2022)
Article
Materials Science, Multidisciplinary
Joseph A. Otte, Jin Zou, Matthew S. Dargusch
Summary: This study demonstrates the successful production of high-performance titanium matrix composites (TMCs) using selective laser melting (SLM) and nanosized BN powder additives. The addition of nanosized BN promotes the formation of TiB nanowhiskers and grain refinement, resulting in TMCs with high tensile yield strength and retained ductility.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Jihao Wang, Tong Liu, Liangshun Luo, Xiaoye Cai, Binbin Wang, Junhao Zhao, Zonghui Cheng, Liang Wang, Yanqing Su, Xiang Xue, Jingjie Guo
Summary: In this study, a TiB2/AlMgScZr composite was fabricated using selective laser melting (SLM) and direct powder mixing. The results showed that TiB2 formed a coherent relationship with the matrix and promoted the precipitation of Al3Sc and Al3Zr phases during the SLM process. The SLM-fabricated TiB2/AlMgScZr composites exhibited excellent mechanical properties, surpassing those of conventional wrought Al alloys. However, the high heating and cooling rate in the SLM process weakened the strengthening effect of TiB2 in the composites.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Materials Science, Multidisciplinary
Andrew Reinhart, Troy Ansell, Walter Smith, Andy Nieto
Summary: Selective laser melting (SLM) processing of metal matrix composites (MMCs) presents unique challenges due to dissimilar interfaces and rapid melting. This study found that uniform deposition of oxides can cause issues with powder flowability and melt pool stability, but also improve the mechanical properties of the composites. Composites fabricated under different oxide reinforcement conditions exhibit varying defects and performance at different scales.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2021)
Article
Chemistry, Physical
Debajyoti Bhaduri, Tina Ghara, Pavel Penchev, Soumitra Paul, Catalin Pruncu, Stefan Dimov, David Morgan
Summary: A novel LP strategy was proposed to improve the re-melting of aluminium alloys by introducing a thermally insulating ceramic baseplate, resulting in significant reductions in surface roughness and residual stresses. The study highlights the importance of controlling heat dissipation in laser polishing of thermally conductive materials to achieve desired surface integrity properties.
APPLIED SURFACE SCIENCE
(2021)
Article
Materials Science, Multidisciplinary
Jiangtao Zhang, Guoqin Huang, Yangli Xu, Jianyu Wang, Guangyao Han, Yuanqiang Tan
Summary: Selective laser melting (SLM) provides a novel method for the integrated production of structural and functional metal-matrix diamond composites in the field of diamond tools. In this study, a discrete element method model is developed to simulate the spreading process of diamond/CuSn composite powders. The findings reveal that adjusting the physical properties of diamond particles and process parameters can improve the powder bed quality and particle dynamics, leading to better performance of diamond tools.
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS
(2024)
Review
Chemistry, Physical
Ivan A. Pelevin, Anton Yu Nalivaiko, Dmitriy Yu Ozherelkov, Alexander S. Shinkaryov, Stanislav Chernyshikhin, Alexey N. Arnautov, Sergey Zmanovsky, Alexander A. Gromov
Summary: This review discusses the application of selective laser melting (SLM) in the fabrication of aluminum matrix composites (AMCs) with alumina reinforcement. The study shows that achieving homogeneous distribution of reinforcing particles and optimizing SLM parameters can lead to improved density, hardness, and tribological properties of the materials.
Article
Chemistry, Physical
Hailong Liao, Wenqi Zhang, Changpeng Chen, Baijin Chen, Gang Xue, Haihong Zhu
Summary: In this study, near full density and crack-free hybrid aluminum matrix composites (HAMCs) reinforced with Cr3C2 ceramic particles and Ni-Cr trace elements were successfully fabricated using selective laser melting (SLM). The incorporation of trace elements Ni and Cr led to the formation of various intermetallic compounds, providing significant precipitation strengthening effect. The load transfer from matrix to the reinforcing particles and the formation of acicular Al4C3 at the interface between Cr3C2 and the matrix played important roles in strengthening the metal matrix composites. The HAMCs exhibited a 32% increase in microhardness and a 22% increase in compressive strength, but a significant reduction (26%) in tensile properties due to the sensitivity of the ceramic particle cracks to tensile stress.
Article
Engineering, Multidisciplinary
Zhiguang Zhou, Yunzhong Liu, Xiaohui Liu, Qiangkun Zhan, Kaidong Wang
Summary: In situ TiB reinforced titanium matrix composites were fabricated via selective laser melting, with optimized processing to achieve crack-free and fully dense composites. The distribution of TiB reinforcement in the composites was mainly in the form of whisker clusters, showing different distributions in TMC1 and TMC2. The improvement in mechanical properties of the composites was attributed to Hall-Petch strengthening and load-bearing transformation strengthening.
COMPOSITES PART B-ENGINEERING
(2021)
Article
Engineering, Chemical
Kaijie Lin, Yamei Fang, Dongdong Gu, Qing Ge, Jie Zhuang, Lixia Xi
Summary: Graphene is used as reinforcement in titanium matrix composites (TMCs) to enhance performance, with selective laser melting (SLM) showing great potential in fabrication. The study investigated the effects of ball milling time on properties of composite powder and formability of SLM. Results showed that 5-hour ball-milled composite powder had good sphericity and flowability. The optimized SLM-processed graphene reinforced TMCs exhibited higher microhardness and tensile strength compared to SLM-processed TC4.
ADVANCED POWDER TECHNOLOGY
(2021)
Article
Optics
Jianbo Jin, Shengfeng Zhou, Yu Zhao, Qiang Zhang, Xiaojian Wang, Wei Li, Dongchu Chen, Lai-Chang Zhang
Summary: The study investigated the effect of TiB2 content on the microstructure and wear resistance of titanium matrix composites fabricated by selective laser melting. It was found that increasing TiB2 content refined the microstructure and improved the wear resistance by inducing strengthening and hardening effects. Additionally, the in-situ reaction of TiB2 with Ti matrix during SLM resulted in the formation of TiB and refinement of Ti matrix, leading to enhanced properties of the composites.
OPTICS AND LASER TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Chunguo Zhang, Xiaozhi Hu, Tim Sercombe, Qingbin Li, Zhimin Wu, Pengmin Lu
Article
Materials Science, Multidisciplinary
C. D. Rabadia, Y. J. Liu, S. F. Jawed, L. Wang, Y. H. Li, X. H. Zhang, T. B. Sercombe, H. Sun, L. C. Zhang
MATERIALS & DESIGN
(2018)
Article
Nanoscience & Nanotechnology
J. C. Wang, Y. J. Liu, P. Qin, S. X. Liang, T. B. Sercombe, L. C. Zhang
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2019)
Article
Engineering, Manufacturing
Y. J. Liu, D. C. Ren, S. J. Li, H. Wang, L. C. Zhang, T. B. Sercombe
ADDITIVE MANUFACTURING
(2020)
Article
Chemistry, Physical
Shengfeng Zhou, Yu Zhao, Xiaojian Wang, Wei Li, Dongchu Chen, T. B. Sercombe
JOURNAL OF ALLOYS AND COMPOUNDS
(2020)
Article
Materials Science, Multidisciplinary
Jincheng Wang, Yujing Liu, Chirag Dhirajlal Rabadia, Shun-Xing Liang, Timothy Barry Sercombe, Lai-Chang Zhang
Summary: This study investigates the microstructure and mechanical properties of a SLM-produced Ti-35Nb composite using elemental powder, revealing the benefits of solid-solution treatment in enhancing chemical homogeneity and bonding strength. Analyses of tensile fractures and shear bands confirm the correlation between different phases and the ductility of Ti-35Nb.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2021)
Article
Materials Science, Ceramics
Neda Ghaebi Panah, Rob Atkin, Timothy B. Sercombe
Summary: Mesoporous glass 58S has excellent bioactivity and strength. However, sintering can lead to crystallization, reducing bioactivity. The occurrence of segregation can affect the material properties of post-sintered glasses.
CERAMICS INTERNATIONAL
(2021)
Article
Materials Science, Multidisciplinary
J. C. Wang, Y. J. Liu, S. X. Liang, Y. S. Zhang, L. Q. Wang, T. B. Sercombe, L. C. Zhang
Summary: This study investigates the microstructure and mechanical behavior of Ti-35Nb alloy components manufactured using different types of powder feedstock, highlighting the importance of powder feedstock on the melt pool stability and resultant part's microstructure and mechanical properties.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Sami E. Alkhatib, Timothy B. Sercombe
Summary: Understanding the high strain-rate response of materials is crucial in various applications, and the advancements in additive manufacturing have made it possible to produce lightweight structures using light metal alloys. However, research on the dynamic response of additive manufacturing materials is limited.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Ceramics
Rob Atkin, Timothy B. Sercombe, Neda Ghaebi Panah
Summary: Bioactive glass scaffolds are commonly used in bone tissue engineering applications, and sintering is often employed to enhance their mechanical strength. However, sintering can lead to crystallization, resulting in reduced bioactivity and biodegradability. This study compared the in-vitro bioactivity and biodegradability of sintered 58S bioactive glass made from fully amorphous powder and partially crystalline powder with the same chemical compositions. The results showed that the sintered 58S produced from glass ceramic powder exhibited higher in-vitro bioactivity and biodegradability rate than that from fully amorphous powder. The initial structure after calcination was found to be crucial in determining the subsequent crystallization during sintering, and the presence of crystallinity and hydroxyapatite formation after calcination played important roles in increasing the bioactivity and biodegradability rate of the sintered 58S.
JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
(2022)
Article
Engineering, Civil
Sami E. Alkhatib, Ali Karrech, Timothy B. Sercombe
Summary: Lightweight lattice structures have gained much attention in various fields due to their high specific mechanical properties. This study investigates the energy absorption of a 3D printed titanium-based isotropic lattice structure. The results show that the topology optimized lattice exhibits excellent energy absorption isotropy and comparable performance to other lattice structures.
THIN-WALLED STRUCTURES
(2023)
Article
Materials Science, Multidisciplinary
Vivien J. Challis, Xiaoxue Xu, Angela Halfpenny, Andrew D. Cramer, Martin Saunders, Anthony P. Roberts, T. B. Sercombe
Summary: Due to their low Young's Modulus, high strength and suitability for additive manufacturing, non-toxic beta-type titanium alloys are emerging as next-generation biomaterials. We present novel experimental results that demonstrate significant variation of Young's Modulus with direction for selective laser melted (SLM) biocompatible Ti-24Nb-4Zr-8Sn (Ti2448). Computational models accurately predict the anisotropic Young's Modulus of polycrystalline materials and show how to tailor the modulus of SLM components by choosing the build orientation in the context of biocompatible Ti2448.
Article
Materials Science, Multidisciplinary
Sami E. Alkhatib, Shanqing Xu, Guoxing Lu, Ali Karrech, Timothy B. Sercombe
Summary: Laser powder bed fused (LPBFed) metal alloys, such as titanium, aluminium, and steel, have high specific strength and great potential in the automotive and aerospace sectors. This study investigated the dynamic behavior of LPBFed CPTi, AlSi10Mg, and 316L stainless steel under strain rates of approximately 500-3000 s-1. The results showed that LPBFed CPTi exhibited higher flow stress than conventionally built counterparts due to the fine grain size resulting from the additive manufacturing method.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Electrical & Electronic
Ben T. McAllister, Jeremy Bourhill, Wing Him Jacob Ma, Tim Sercombe, Maxim Goryachev, Michael E. Tobar
Summary: This study presents an experimental characterization of the electrical properties of 3-D-printed niobium, demonstrating its superconducting transition and surface resistance. The research also introduces a simple method for characterizing material properties of a sample of superconductor, which could be easily applied to other materials. Further research in additive manufacturing may lead to the future application of 3-D-printed niobium in superconducting cavity designs and other innovative technologies.
IEEE TRANSACTIONS ON INSTRUMENTATION AND MEASUREMENT
(2021)
Article
Materials Science, Multidisciplinary
Y. Ma, G. Ji, X. P. Li, C. Y. Chen, Z. Q. Tan, A. Addad, Z. Q. Li, T. B. Sercombe, J. P. Kruth