Additive Manufacturing of Metal Alloys 2

Patrice Peyre is a CNRS senior research scientist at the PIMM laboratory in Paris. He specializes in the study of the transformation of materials using lasers.Éric Charkaluk is a CNRS senior research scientist at the LMS laboratory at École Polytechnique near Paris. His interests include the deformation and damage of metals in relation to their microstructure.

• Introduction ixPatrice PEYRE and Éric CHARKALUKChapter 1 Microstructures of Metallic Materials from Additive Manufacturing 1Coordinated by Christophe COLIN1.1 Solidification microstructures from AM processes 51.1.1 Introduction 61.1.2 Growth kinetics with local interface equilibrium 91.1.3 Loss of local interface equilibrium at high solidification rates 111.1.4 Growth morphologies 141.1.5 Growth competition between microstructures 171.1.6 Selection of grain structures 191.1.7 Solidification in additive manufacturing 221.1.8 Acknowledgments 231.2 Microstructures of steels 231.2.1 Steels and additive manufacturing 231.2.2 Rapid solidification of steels in AM 241.2.3 Phases and phase transformations 271.2.4 Cold cracking 341.2.5 Examples of as-built microstructures 351.2.6 Summary of microstructural features of steels 381.3 Microstructures of nickel-based superalloys 391.3.1 Nickel-based superalloys and their applications 391.3.2 General information on the metallurgy of nickel-based superalloys 391.3.3 Two families of superalloys 411.3.4 Microstructures of nickel-based alloys resulting from AM: weldable alloys 421.3.5 Hard-to-weld superalloys 481.3.6 Overview of the microstructures of superalloys 541.4 Microstructures of titanium alloys 541.4.1 Phases and phase transformations 551.4.2 Microstructures of titanium alloys resulting from the DED process 571.4.3 Microstructures of titanium alloys from the L-PBF process 621.4.4 Microstructures of titanium alloys from the E-PBF process 681.4.5 Overview of the microstructures of titanium alloys 731.5 Microstructures of aluminum alloys 741.5.1 Microstructures induced by L-PBF 741.5.2 Microstructures induced by WAAM on aluminum 821.5.3 Microstructures induced by DED-LMD 851.5.4 Summary of the microstructures of aluminum alloys 871.6 Conclusion 881.7 References 89Chapter 2 Post-processing in Additive Manufacturing 99Coordinated by Brigitte BACROIX2.1 Surface treatments 992.1.1 Introduction 992.1.2 Aqueous processes 1012.1.3 Mechanical processes 1142.1.4 Physical processes: example of laser polishing 1262.1.5 Summary of surface treatments 1292.2 Hot isostatic pressing 1312.2.1 Introduction 1312.2.2 Reminder of the mechanisms active during HIP and standard processing 1322.2.3 Main microstructural modifications caused by HIP post-treatment 1352.2.4 Link between HIP and mechanical properties for titanium and nickel alloys 1382.2.5 Overview of HIP 1412.3 Heat treatments 1412.3.1 Stress-relieving treatments 1422.3.2 Homogenization treatments 1452.3.3 Precipitation and structural hardening 1502.3.4 Summary of heat treatments for AM 1522.4 Conclusion 1542.5 References 155Chapter 3 The Properties of Parts Produced by Additive Manufacturing 163Coordinated by Éric CHARKALUK3.1 Static mechanical properties 1643.1.1 Test specimens 1643.1.2 Tensile properties in the as-built case 1683.1.3 Effect of post-processing on tensile properties 1723.1.4 Some indications regarding deformation mechanisms 1753.1.5 Partial conclusions on the tensile properties of alloys obtained by additive manufacturing 1773.2 Fatigue behavior 1773.2.1 General fatigue properties 1783.2.2 Defects 1803.2.3 Living with defects 1833.2.4 Post-processing of parts 1883.2.5 Partial conclusions on the fatigue properties of alloys obtained by additive manufacturing 1893.3 Creep behavior and resistance 1903.3.1 Creep deformation mechanisms 1913.3.2 Creep tests 1923.3.3 Creep behavior 1943.3.4 Damage and service life 2003.3.5 Partial conclusions on the creep properties of additive manufacturing materials 2013.4 Aqueous and high temperature corrosion of alloys produced by additive manufacturing 2023.4.1 Effect of chemical composition 2023.4.2 Effect of microstructure 2033.4.3 Effect of manufacturing defects 2073.4.4 Effect of surface roughness 2083.4.5 Effect of residual stresses 2103.4.6 Effect of complex geometries and thin walls 2103.4.7 Effect of pre-oxidation during HIP treatment 2113.4.8 Alloys developed specifically for additive manufacturing 2113.4.9 Partial conclusions on the corrosion performance of alloys resulting from additive manufacturing 2123.5 Properties of architectured materials 2133.5.1 Application examples 2153.5.2 Specificities related to the additive manufacturing of architectured materials 2263.5.3 Partial conclusions on the properties of architectured materials 2383.6 Conclusion 2393.7 References 239Conclusion 253Patrice PEYRE and Éric CHARKALUKAbbreviations 255List of Authors 265Index 269