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Advances in Metal Additive Manufacturing Woodhead Publishing Reviews: Mechanical Engineering Series Advances in Metal Additive Manufacturing Edited by Sachin Salunkhe Sergio T. Amancio-Filho J. Paulo Davim Preface An essential benefit of additive manufacturing (AM) is the ability to create more complicated parts with better mechanical and thermal performance and lower sys- tem mass than is possible with other manufacturing methods. AM design’s inherent complexity permits lightweight by consolidating multiple components into one, allowingforincreasedtechnicalefficacy. The book is focused on various applications of metal additive manufacturing suchasaerospace,defence,automotive,consumerproducts,industrialproducts,and medical devices. All chapters of this book present the results of the dedicated research efforts of authors for years. The book highlights the latest research status innotonly thedomainbutalsoidentifiesthe futurescopeofworkforyounggradu- ates, engineers, and senior R&D professionals working in the field of metal manufacturing. There is no doubt that additive manufacturing industries will also bebenefitedbytheresearchworkreportedinvariouschaptersofthisbook. The book not only highlights the latest research status in the domain but also identifies the future scope of work for young researchers, mechanical and materials engineering students, and professionals willing to learn the fundamentals and recent advancesinmetaladditivemanufacturing. The book provides feature information related to metal additive manufacturing processessuchaspowder bedfusion(e.g.,selectivelaser melting)techniques,wire- and powder-based direct energy deposition processes using high energy beams, or those hybrid processes that combine both additive and subtractive manufacturing (SM)methodsmayallfallunderthecategoryofAM. The book’s structure provides a guideline of where to start, what to learn, how it all fits together, and how metal additive manufacturing can empower you to think beyond conventional metal processing. In addition, case studies, recent examples, and technology applications are provided to reveal current applications and future potential. We would like to thank all book chapter authors for their valuable contribution to this book project, and Elsevier and Brian Guerin, Holland-Borosh, Clodagh, and Rafael G. Trombaco for the invaluable help in the organisation of the editing pro- cess. Last but notleast, the editors would like to thank Rafael Paiotti (TU Graz) for hisvaluablesupportwiththeinternalbookreview activities. SachinSalunkhe SergioT.Amancio-Filho J.PauloDavim List of contributors M.M. Abdel-Mottaleb Production Engineering and Printing Technology Department,AkhbarElYomAcademy,Giza,Egypt Bader Alqahtani Mechanical Engineering Department, College of Engineering, NorthernBorderUniversity,Arar,SaudiArabia Sergio T. Amancio-Filho Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, High Performance and Lightweight MaterialsGroup,GrazUniversityofTechnology,Graz,Styria,Austria S. Anand Kumar Additive Manufacturing Research Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Jammu, Jammu & Kashmir,India Siegfried Arneitz Institute of Materials Science, Joining and Forming, Graz UniversityofTechnology,Graz,Styria,Austria Ricardo Henrique Buzolin Institute of Materials Science, Joining and Forming, GrazUniversityofTechnology,Graz,Styria,Austria Pedro dos Santos Effertz Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, High Performance and Lightweight MaterialsGroup,GrazUniversityofTechnology,Graz,Styria,Austria Abou Bakr Elshalakany Production Engineering and Printing Technology Department,AkhbarElYomAcademy,Giza,Egypt Norbert Enzinger Institute of Materials Science, Joining and Forming, Joining Group,GrazUniversityofTechnology,Graz,Styria,Austria Carlos Alberto Feliciano Belei Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, High Performance and LightweightMaterialsGroup,GrazUniversityofTechnology,Graz,Styria,Austria Jochen Giedenbacher Centre for Smart Manufacturing, Upper Austria University ofAppliedSciences,Wels,UpperAustria,Austria xii Listofcontributors Rafael Paiotti M. Guimara˜es Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, High Performance and Lightweight MaterialsGroup,GrazUniversityofTechnology,Graz,Styria,Austria Franz Haas Institute of Materials Science, Joining and Forming, Graz University ofTechnology,Graz,Styria,Austria AzizHuskic CentreforSmartManufacturing,UpperAustriaUniversityofApplied Sciences,Wels,UpperAustria,Austria C.T. Justus Panicker Department of Production Engineering, National Institute of TechnologyTiruchirappalli,Tiruchirappalli,TamilNadu,India M. Kumaran Department of Production Engineering, National Institute of TechnologyTiruchirappalli,Tiruchirappalli,TamilNadu,India Benjamin Meier Joanneum Research, Materials Institute for Laser and Plasma Technology,Niklasdorf,Styria,Austria Lisa Minkowitz Institute of Materials Science, Joining and Forming, Graz UniversityofTechnology,Graz,Styria,Austria Marcel Mu¨ller Centre for Smart Manufacturing, Upper Austria University of AppliedSciences,Wels,UpperAustria,Austria Florian Pixner Institute of Materials Science, Joining and Forming, Joining Group,GrazUniversityofTechnology,Graz,Styria,Austria Prasad Raghupatruni Department of Chemical, Materials and Metallurgical Engineering, Botswana International University of Science and Technology (BIUST),Palapye,Botswana D. Rajamani Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology,Chennai,TamilNadu,India Samrat Rao Additive Manufacturing Research Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Jammu, Jammu & Kashmir,India Sachin Salunkhe Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science andTechnology,Chennai,TamilNadu,India T. Sathies Department of Production Engineering, National Institute of TechnologyTiruchirappalli,Tiruchirappalli,TamilNadu,India Listofcontributors xiii V. Senthilkumar Department of Production Engineering, National Institute of TechnologyTiruchirappalli,Tiruchirappalli,TamilNadu,India Abhishek Shrivastava Additive Manufacturing Research Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Jammu, Jammu & Kashmir,India Mateusz Skalon Institute of Materials Science, Joining and Forming, BMK Endowed Professorship for Aviation, High Performance and Lightweight Materials Group,GrazUniversityofTechnology,Graz,Styria,Austria Christof Sommitsch Institute of Materials Science, Joining and Forming, High Performance and Lightweight Materials Group, Graz University of Technology, Graz,Austria Norbert Wild Centre for Smart Manufacturing, Upper Austria University of AppliedSciences,Wels,UpperAustria,Austria WoodheadPublishingisanimprintofElsevier 50HampshireStreet,5thFloor,Cambridge,MA02139,UnitedStates TheBoulevard,LangfordLane,Kidlington,OX51GB,UnitedKingdom Copyright©2023ElsevierLtd.Allrightsreserved. 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Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgein evaluatingandusinganyinformation,methods,compounds,orexperimentsdescribed herein.Inusingsuchinformationormethodstheyshouldbemindfuloftheirownsafety andthesafetyofothers,includingpartiesforwhomtheyhaveaprofessionalresponsibility. Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,or editors,assumeanyliabilityforanyinjuryand/ordamagetopersonsorpropertyasamatter ofproductsliability,negligenceorotherwise,orfromanyuseoroperationofanymethods, products,instructions,orideascontainedinthematerialherein. ISBN:978-0-323-91230-3(print) ISBN:978-0-323-91468-0(online) ForinformationonallWoodheadPublishingpublications visitourwebsiteathttps://www.elsevier.com/books-and-journals Publisher:MatthewDeans AcquisitionsEditor:BrianGuerin EditorialProjectManager:ClodaghHolland-Borosh/ RafaelGuilhermeTrombaco ProductionProjectManager:SuryaNarayananJayachandran CoverDesigner:MilesHitchen TypesetbyMPSLimited,Chennai,India Contents Listofcontributors xi Preface xv 1. Powderbedfusionprocesses:mainclassesofalloys, currentstatus,andtechnologicaltrends 1 RafaelPaiottiM.Guimara˜es,LisaMinkowitz,SiegfriedArneitz, ChristofSommitsch,JochenGiedenbacher,MarcelMu¨ller,AzizHuskic, NorbertWild,RicardoHenriqueBuzolin,BenjaminMeier, MateuszSkalon,FranzHaasandSergioT.Amancio-Filho 1.1 Additivemanufacturingofaluminumalloys 1 1.1.1 Generalchallenges 1 1.1.2 Overviewoveraluminumalloysproducedbyadditive manufacturing 4 1.1.2.1 AlSi10Mg 5 1.1.2.2 AlSi12 5 1.1.2.3 Sc,Zr-basedaluminumalloys 7 1.1.2.4 Al-Cualloys 7 1.1.2.5 AA7075alloys 8 1.1.2.6 AA6061alloys 9 1.2 Laserpowderbedfusionoftoolsteels 9 1.2.1 Hotworktoolsteels 9 1.2.2 High-speedsteelsandcoldworktoolsteels 13 1.3 Lasermetaldepositionofsteels 15 1.3.1 Introduction 15 1.3.2 LMDoftoolsteels 15 1.3.3 Conclusion 21 1.4 Powder-basedadditivemanufacturingofshapememoryalloys 22 1.4.1 Introduction 22 1.4.2 Powder-basedadditivemanufacturingofshapememory alloys:currenttechnologiesinuse 23 1.4.3 ProcessingofNiTi-basedalloys:fieldsofapplication 29 1.4.4 ProcessingofotherSMAalloysbypowder-basedadditive manufacturing 30 1.5 Powder-basedadditivemanufacturingofhigh-entropyalloys 32 1.5.1 Introduction 32 1.5.2 Technologicaloverview 33 1.5.3 PowderforHEAdevelopment 34 vi Contents 1.5.4 Techniques for3DprintingofHEAs 35 1.5.5 Mechanicalpropertiesof3D-printedHEAs 47 1.6 Powder-basedadditivemanufacturingofmagneticmaterials 52 1.6.1 Additivemanufacturingofhardmagneticmaterials 52 1.6.2 Nd-Fe-B 53 1.6.3 Fe-Co-basedmagneticalloys 56 1.6.4 Additivemanufacturingofsoftmagneticmaterials 58 1.7 Insitualloying 60 1.7.1 Introduction 60 1.7.2 Powderqualityandmixing 60 1.7.3 Thetemperatureofmelting,energyinput,andhomogeneity 62 1.8 AMofrecycledTi-64powder 66 1.8.1 Introduction:whyreusethepowder? 66 1.8.2 Influenceonthepowder 66 1.8.3 Influenceonbuildparts 69 1.8.4 Influenceonthemechanical properties 69 1.9 Outlook:newpowder-basedadditivemanufacturingprocesses 71 1.9.1 SelectiveLED-basedmelting 71 1.10 Sintering-debindingadditivemanufacturing 73 1.10.1 BinderJetting 73 1.10.2 Metalextrusionadditivemanufacturingof highlyfilledpolymers 75 1.10.3 Lithography-basedmetalmanufacturing 76 1.11 Coldsprayadditivemanufacturing 78 References 82 2. Directedenergydepositionprocessesandprocessdesignby artificialintelligence 105 RafaelPaiottiM.Guimara˜es,FlorianPixner,NorbertEnzinger, CarlosAlbertoFelicianoBelei,PedrodosSantosEffertzand SergioT.Amancio-Filho 2.1 Wire-arc additivemanufacturing 105 2.1.1 Introduction 105 2.1.2 ArcweldingtechniquesinWAAM:coldmetaltransferin comparisontogasmetalarcwelding 105 2.1.3 Materialsdevelopmentusingfillerwire:solidwire comparedtometalcoredwires 108 2.2 Wire-basedelectronbeamadditivemanufacturingof titaniumalloysandNiTishapememoryalloys 112 2.2.1 Introduction 112 2.2.2 Wire-basedelectronbeamadditivemanufacturing 112 2.2.3 Wire-basedelectronbeamadditivemanufacturingof titaniumalloys 115 2.2.4 Wire-basedelectronbeamadditivemanufacturingof NiTishapememoryalloys 118