Assessing and controlling microstructure heterogeneity in fusion-based additive manufacturing

M Seita
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Abstract

One of the de*ining features of fusion-based additive manufacturing (AM) is the localized melting of metal by a high-energy source, which fuses the material together point by point and layer by layer into a 3D object. The rapid solidi*ication velocity, directional thermal gradients, and site-speci*ic thermal build-ups produced by this process yield parts with complex and heterogeneous microstructure. This heterogeneity is a double-edged sword. On the one hand, it leads to large property scatter and casts uncertainty over parts performance, hindering the adoption of additive technologies by the industry. On the other hand, it may impart exceptional mechanical properties and new functionalities, which are not found in conventionally produced materials. In this paper, we present two ongoing research endeavours aimed at mitigating the detrimental effects of microstructure heterogeneity in AM, and at capitalizing on the opportunities it offers in the design of novel metal alloys, respectively. The *irst consists of developing a high-throughput characterization technique to enable large-scale microstructure analysis of AM builds. The second consists of a new strategy to control the material’s microstructure site-speci*ically during laser powder bed fusion.
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评估和控制基于熔融技术的增材制造中的微结构异质性
基于熔融技术的增材制造(AM)的一个显著特点是通过高能源对金属进行局部熔化,将材料逐点逐层熔合成三维物体。这种工艺所产生的快速凝固速度、定向热梯度和特定部位的热堆积,使零件具有复杂的异质微观结构。这种异质性是一把双刃剑。一方面,它会导致较大的属性分散,给零件性能带来不确定性,阻碍行业采用添加剂技术。另一方面,它也可能赋予传统材料所不具备的特殊机械性能和新功能。在本文中,我们将介绍两项正在进行的研究工作,其目的分别是减轻 AM 中微观结构异质性的不利影响,以及利用其为新型金属合金设计提供的机遇。第一项研究包括开发一种高通量表征技术,以实现对 AM 制件的大规模微观结构分析。第二项研究包括在激光粉末床熔融过程中控制材料微观结构的新策略。
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