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Virtual and Physical Prototyping Volume 18, 2023 - Issue 1
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Review

Recent progress on microstructure manipulation of aluminium alloys manufactured via laser powder bed fusion

Zhen Xiaoa School of Transportation and Vehicle Engineering, Shandong University of Technology, Zibo, People’s Republic of ChinaORCID Iconhttps://orcid.org/0000-0003-0799-7707View further author information
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Wenhui Yub Shandong Provincial Key Laboratory of Precision Manufacturing and Non-traditional Machining, School of Mechanical Engineering, Shandong University of Technology, Zibo, People’s Republic of ChinaCorrespondence[email protected]
ORCID Iconhttps://orcid.org/0000-0003-1545-2803View further author information
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Hongxun Fua School of Transportation and Vehicle Engineering, Shandong University of Technology, Zibo, People’s Republic of ChinaView further author information
,
Yaoji Dengc School of Mechanical Engineering, Yangzhou University, Yangzhou, People’s Republic of ChinaView further author information
,
Yongling Wub Shandong Provincial Key Laboratory of Precision Manufacturing and Non-traditional Machining, School of Mechanical Engineering, Shandong University of Technology, Zibo, People’s Republic of ChinaORCID Iconhttps://orcid.org/0000-0002-0725-8915View further author information
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Hongyu Zhengb Shandong Provincial Key Laboratory of Precision Manufacturing and Non-traditional Machining, School of Mechanical Engineering, Shandong University of Technology, Zibo, People’s Republic of ChinaORCID Iconhttps://orcid.org/0000-0002-4895-0617View further author information
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Article: e2125880 | Received 03 Sep 2022, Accepted 05 Sep 2022, Published online: 16 Oct 2022

Figures & data

Figure 1. Schematic of (a) a typical LPBF machine, (b) gas circulation system, and (c) LPBF process parameters. Reproduced from Wen et al. (Citation2019) (a and b) and Yap et al. (Citation2015) (c).

Figure 1. Schematic of (a) a typical LPBF machine, (b) gas circulation system, and (c) LPBF process parameters. Reproduced from Wen et al. (Citation2019) (a and b) and Yap et al. (Citation2015) (c).

Figure 2. The illustration of the as-built microstructure formation. Revised from Zhang et al. (Citation2022), Pérez-Ruiz et al. (Citation2021), Thijs et al. (Citation2013), Pantawane et al. (Citation2020).

Figure 2. The illustration of the as-built microstructure formation. Revised from Zhang et al. (Citation2022), Pérez-Ruiz et al. (Citation2021), Thijs et al. (Citation2013), Pantawane et al. (Citation2020).

Figure 3. The computationally predicted thermal pattern in a single laser track. Reproduced from Pantawane et al. (Citation2020).

Figure 3. The computationally predicted thermal pattern in a single laser track. Reproduced from Pantawane et al. (Citation2020).

Figure 4. The computationally predicted thermal pattern of position P in a single layer. Reproduced from Pantawane et al. (Citation2020).

Figure 4. The computationally predicted thermal pattern of position P in a single layer. Reproduced from Pantawane et al. (Citation2020).

Figure 5. The computationally predicted overall thermal history of location P on the surface of lth layer in multiple layer fabrication. Reproduced from Pantawane et al. (Citation2020).

Figure 5. The computationally predicted overall thermal history of location P on the surface of lth layer in multiple layer fabrication. Reproduced from Pantawane et al. (Citation2020).

Figure 6. The influencing factors of thermal histories.

Figure 6. The influencing factors of thermal histories.

Figure 7. (a) The melt pool morphology varying with VED; (b) the illustrations of fish scale pattern in conduction and keyhole melt pool; (c) representative EBSD orientation maps of the front view (left) and top view (right) for an AlSi10Mg alloy LPBF part. Reproduced from Pérez-Ruiz et al. (Citation2021) (a and b) and Thijs et al. (Citation2013) (c).

Figure 7. (a) The melt pool morphology varying with VED; (b) the illustrations of fish scale pattern in conduction and keyhole melt pool; (c) representative EBSD orientation maps of the front view (left) and top view (right) for an AlSi10Mg alloy LPBF part. Reproduced from Pérez-Ruiz et al. (Citation2021) (a and b) and Thijs et al. (Citation2013) (c).

Figure 8. The grain structures at the centre plane in LPBF parts with different N0 with undercooling ΔTc being kept as 5 K. Reproduced from Li and Tan (Citation2018).

Figure 8. The grain structures at the centre plane in LPBF parts with different N0 with undercooling ΔTc being kept as 5 K. Reproduced from Li and Tan (Citation2018).

Figure 9. (a) Solidification map and (b) a representative G–V map. Reproduced from Van Cauwenbergh et al. (Citation2021) (a) and Li and Tan (Citation2018) (b).

Figure 9. (a) Solidification map and (b) a representative G–V map. Reproduced from Van Cauwenbergh et al. (Citation2021) (a) and Li and Tan (Citation2018) (b).

Figure 10. Interactions between LPBF parameters-microstructure-properties. Revised from Pérez-Ruiz et al. (Citation2021).

Figure 10. Interactions between LPBF parameters-microstructure-properties. Revised from Pérez-Ruiz et al. (Citation2021).

Figure 11. SEM images of etched top (−1) and side (−2) of Al–xSi LPBF samples fabricated with the optimal processing parameters. (a) Al–0Si, (b) Al–1Si, (c) Al–4Si, (d) Al–7Si, (e) Al–10Si, (f) Al–12Si, and (g) Al–20Si. Reproduced from Kimura et al. (Citation2017).

Figure 11. SEM images of etched top (−1) and side (−2) of Al–xSi LPBF samples fabricated with the optimal processing parameters. (a) Al–0Si, (b) Al–1Si, (c) Al–4Si, (d) Al–7Si, (e) Al–10Si, (f) Al–12Si, and (g) Al–20Si. Reproduced from Kimura et al. (Citation2017).

Figure 12. Microstructure of the as-built Al-5024 alloy fabricated by LPBF. (a) EBSD orientation map indicating the bimodal structure. (b) HAADF-STEM image of a fine equiaxed grain region with corresponding EDX elemental mapping. (c) Bright-field TEM image within a fine Al equiaxed grain region. (d) The selected area diffraction (SAD) from a single Al grain shown in (c), indicating single-phase Al in the [001] orientation. Reproduced from He et al. (Citation2021).

Figure 12. Microstructure of the as-built Al-5024 alloy fabricated by LPBF. (a) EBSD orientation map indicating the bimodal structure. (b) HAADF-STEM image of a fine equiaxed grain region with corresponding EDX elemental mapping. (c) Bright-field TEM image within a fine Al equiaxed grain region. (d) The selected area diffraction (SAD) from a single Al grain shown in (c), indicating single-phase Al in the [001] orientation. Reproduced from He et al. (Citation2021).

Figure 13. Schematic of early-stage and later-stage solidification within the melt pool, indicating how Sc atom distribution leads to a bimodal structure in the melt pool. Reproduced from He et al. (Citation2021).

Figure 13. Schematic of early-stage and later-stage solidification within the melt pool, indicating how Sc atom distribution leads to a bimodal structure in the melt pool. Reproduced from He et al. (Citation2021).

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