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The purpose of this paper is to investigate the effect of remelting each layer on the homogeneity of nickel-titanium (NiTi) parts fabricated from elemental nickel and titanium powders using laser powder bed fusion (LPBF). In addition, the influence of manufacturing parameters and different melting strategies, including multiple cycles of remelting, on printability and macro defects, such as pore and crack formation, have been investigated.

An LPBF process was used to manufacture NiTi alloy from elementally blended powders and was evaluated with the use of a remelting scanning strategy to improve the homogeneity of fabricated specimens. Furthermore, both single melt and up to two remeltings were used.

The results indicate that remelting can be beneficial for density improvement as well as chemical and phase composition homogenization. Backscattered electron mode in scanning electron microscope showed a reduction in the presence of unmixed Ni and Ti elemental powders in response to increasing the number of remelts. The microhardness values of NiTi parts for the different numbers of melts studied were similar and ranged from 487 to 495 HV. Nevertheless, it was observed that measurement error decreases as the number of remelts increases, suggesting an increase in chemical and phase composition homogeneity. However, X-ray diffraction analysis revealed the presence of multiple phases regardless of the number of melt runs.

For the first time, to the best of the authors’ knowledge, elementally blended NiTi powders were fabricated via LPBF using remelting scanning strategies.

This paper aims to present a comprehensive review of the laser engineered net shaping (LENS) process in an attempt to provide the reader with a deep understanding of the controllable and fixed build parameters of metallic parts. The authors discuss the effect and interplay between process parameters, including: laser power, scan speed and powder feed rate. Further, the authors show the interplay between process parameters is pivotal in achieving the desired microstructure, macrostructure, geometrical accuracy and mechanical properties.

In this manuscript, the authors review current research examining the process inputs and their influences on the final product when manufacturing with the LENS process. The authors also discuss how these parameters relate to important build aspects such as melt-pool dimensions, the volume of porosity and geometry accuracy.

The authors conclude that studies have greatly enriched the understanding of the LENS build process, however, much studies remains to be done. Importantly, the authors reveal that to date there are a number of detailed theoretical models that predict the end properties of deposition, however, much more study is necessary to allow for reasonable prediction of the build process for standard industrial parts, based on the synchronistic behavior of the input parameters.

This paper intends to raise questions about the possible research areas that could potentially promote the effectiveness of this LENS technology.

This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It reviews the emerging technologies in PBF multimaterial printing and summarizes the latest simulation approaches for modeling them. The topic of “multimaterial PBF techniques” is still very new, undeveloped, and of interest to academia and industry on many levels.

This is a review paper. The study approach was to carefully search for and investigate notable works and peer-reviewed publications concerning multimaterial three-dimensional printing using PBF techniques. The current methodologies, as well as their advantages and disadvantages, are cross-compared through a systematic review.

The results show that the development of multimaterial PBF techniques is still in its infancy as many fundamental “research” questions have yet to be addressed before production. Experimentation has many limitations and is costly; therefore, modeling and simulation can be very helpful and is, of course, possible; however, it is heavily dependent on the material data and computational power, so it needs further development in future studies.

This work investigates the multimaterial PBF techniques and discusses the novel printing methods with practical examples. Our literature survey revealed that the number of accounts on the predictive modeling of stresses and optimizing laser scan strategies in multimaterial PBF is low with a (very) limited range of applications. To facilitate future developments in this direction, the key information of the simulation efforts and the state-of-the-art computational models of multimaterial PBF are provided.

This paper aims to present an investigation into the variation of scan vector hatch rotation strategies in selective laser melting (SLM), focussing on how it effects density, surface roughness, tensile strength and residual stress.

First the optimum angle of hatch vector rotation is proposed by analysing the effect of different increment angles on distribution of scan vectors. Sectioning methods are then used to determine the effect that the chosen strategies have on the density of the parts. The top surface roughness was analysed using optical metrology, and the tensile properties were determined using uni-axial tensile testing. Finally, a novel multi-support deflection geometry was used to quantify the effects of rotation angles on residual stress.

The results of this research showed that the hatch rotation angle had little effect on the density, top surface roughness and strength of the parts. The greatest residual stress deflection was measured parallel to unidirectional scan vectors. The use of hatch rotations other than alternating 90° showed little benefit in lowering the magnitude of residual stresses. However, the use of rotation angles with a good suitability measure distributes stresses in all directions more evenly for certain part geometries.

All samples produced in this work were made from commercially pure titanium, therefore care must be taken when applying these results to other materials.

This paper serves to increase the understanding of SLM scanning strategies and their effect on the properties of the material.

The purpose of this study is to verify how the carbon doping of the WC-Co cemented carbide (CC) affected their structure before their processing by hot isostatic pressing (HIP) technology.

The samples for this experiment were fabricated by selective laser melting technology (SLM) using a YAG fiber laser with a power of P = 40 W and a scanning speed of 83 mm/s. The subsequent carbon doping process was performed in a chamber furnace at 900 0 C for 1, 4 and 12 h. The HIP was performed at 1,390°C and pressures of 40 MPa, 80 MPa and 120 MPa. The changes induced in the structures were evaluated using X-ray diffraction and various microscopic methods.

X-ray diffraction analysis showed that the structure of the samples after SLM consisted of WC, W₂C, Co₄W₂C and Co phases. As a result of the increase in the carbon content in the structure of the samples, the transition carbide W₂C and structural phase Co₄W₂C decayed. Their decay was manifested by the coarsening of the minor alpha phase (WC), which occurred both during the carburizing process and during the subsequent processing using HIP. In the samples in which the structure was carburized prior to HIP, only the structural phases WC and Co were observed in most cases.

The results confirm that it is possible to increase the homogeneity of the CC structure and thus its applicability in practice by additional carburization of the sample structure with subsequent processing by HIP technology.

The purpose of this paper is to introduce an approach in measuring the shielding gas flow within laser powder bed fusion (L-PBF) machines under near-process conditions (regarding oxygen content and shielding gas flow).

The measurements are made sequentially using a hot-wire anemometer. After a short introduction into the measurement technique, the system which places the measurement probe within the machine is described. Finally, the measured shielding gas flow of a commercial L-PBF machine is presented.

An approach to measure the shielding gas flow within SLM machines has been developed and successfully tested. The use of a thermal anemometer along with an automated probe-placement system enables the space-resolved measurement of the flow speed and its turbulence.

The used single-normal (SN) hot-wire anemometer does not provide the flow vectors’ orientation. Using a probe with two or three hot-films and an improved placement system will provide more information about the flow and less disturbance to it.

A measurement system which allows the measurement of the shielding gas flow within commercial L-PBF machines is presented. This enables the correlation of the shielding gas flow with the resulting parts’ quality.

Powder bed-based additive manufacturing (AM) is a promising family of technologies for industrial applications. The purpose of this study is to provide a new metrics based on the analysis of the compaction behavior for the evaluation of flowability of AM powders.

In this work, a novel qualification methodology based on a camera mounted onto a commercially available tap density meter allowed to assess the compaction behavior of a selection of AM materials, both polymers and metals. This methodology automatizes the reading of the powder height and obtains more information compared to ASTM B527. A novel property is introduced, the “tapping modulus,” which describes the packing speed of a powdered material and is related to a compression/vibration powder flow.

The compaction behavior was successfully correlated with the dynamic angle of repose for polymers, but interestingly not for metals, shedding more light to the different flow behavior of these materials.

Because of the chosen materials, the results may lack generalizability. For example, the application of this methodology outside of AM would be interesting.

This paper suggests a new methodology for assessing the flowing behavior of AM materials when subjected to compression. The device is inexpensive and easy to implement in a quality assurance environment, being thus interesting for industrial applications.

This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).

PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.

Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.

This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

The purpose of this paper is to report on the developments in manufacturing soft magnetic materials using laser powder bed fusion (L-PBF).

Ternary soft magnetic Fe-49Co-2V powder was produced by gas atomization and used in an L-PBF machine to produce samples for material characterization. The L-PBF process parameters were optimized for the material, using a design of experiments approach. The printed samples were exposed to different heat treatment cycles to improve the magnetic properties. The magnetic properties were measured with quasi-static direct current and alternating current measurements at different frequencies and magnetic flux densities. The mechanical properties were characterized with tensile tests. Electrical resistivity of the material was measured.

The optimized L-PBF process parameters resulted in very low porosity. The magnetic properties improved greatly after the heat treatments because of changes in microstructure. Based on the quasi-static DC measurement results, one of the heat treatment cycles led to magnetic saturation, permeability and coercivity values comparable to a commercial Fe-Co-V alloy. The other heat treatments resulted in abnormal grain growth and poor magnetic performance. The AC measurement results showed that the magnetic losses were relatively high in the samples owing to formation of eddy currents.

The influence of L-PBF process parameters on the microstructure was not investigated; hence, understanding the relationship between process parameters, heat treatments and magnetic properties would require more research.

The relationship between microstructure, chemical composition, heat treatments, resistivity and magnetic/mechanical properties of L-PBF processed Fe-Co-V alloy has not been reported previously.

Three-dimensional printing (3DP) is an established process to print structural parts of metals, ceramic and polymers. Further, multi-material 3DP has the potentials to be a milestone in rapid manufacturing (RM), customized design and structural applications. Being compatible as functionally graded materials in a single structural form, multi-material-based 3D printed parts can be applied in structural applications to get the benefit of modified properties.

The fused deposition modelling (FDM) is one of the established low cost 3DP techniques which can be used for printing functional/ non-functional prototypes in civil engineering applications.

The present study is focused on multi-material printing of primary recycled acrylonitrile butadiene styrene (ABS), polylactic acid (PLA) and high impact polystyrene (HIPS) in composite form. Thermal (glass transition temperature and heat capacity) and mechanical properties (break load, break strength, break elongation, percentage elongation at break and Young’s modulus) have been analysed to observe the behaviour of multi-material composites prepared by 3DP. This study also highlights the process parameters optimization of FDM supported with photomicrographs.

The present study is focused on multi-material printing of primary recycled ABS, PLA and HIPS in composite form.