Classification and analysis of common simplifications in part-scale thermal modelling of metal additive manufacturing processes

Computational process modelling of metal additive manufacturing has gained significant research attention in recent past. The cornerstone of many process models is the transient thermal response during the AM process. Since deposition-scale modelling of the thermal conditions in AM is computationally expensive, spatial and temporal...

Achieving superelasticity in additively manufactured Ni-lean NiTi by crystallographic design

Superelastic metallic materials possessing large recoverable strains are widely used in automotive, aerospace and energy conversion industries. Superelastic materials working at high temperatures and with a wide temperature range are increasingly required for demanding applications. Until recently, high-temperature superelasticity has only...

Mechanical and shape memory properties of NiTi triply periodic minimal surface structures fabricated by laser powder bed fusion

Porous NiTi lattice structures are widely used in the manufacture of crucial components owing to their excellent shape memory effect, superelasticity, and high damping capacities. However, the specific strength and lightweight characteristics of porous NiTi lattice structures fabricated by conventional technologies are limited by...

Laser shape variation influence on melt pool dynamics and solidification microstructure in laser powder bed fusion

The shape variation of the laser beam is evidently observed in the laser powder bed fusion (LPBF) process because of changes in laser incidence angle and misalignment between the build plate and the laser focus plane. This issue is particularly relevant in large-scale LPBF systems where the laser beam needs to scan a large build area. However...

Effect of heat treatment on microstructure and functional properties of additively manufactured NiTi shape memory alloys

Additive manufacturing of NiTi shape memory alloys has attracted attention in recent years, due to design flexibility and feasibility to achieve four-dimensional (4D) function response. To obtain customized 4D functional responses in NiTi structures, tailorable phase transformation temperatures and stress windows as well as one-way or two-way...

Healing cracks in additively manufactured NiTi shape memory alloys

The pursuit of enhancing NiTi superelasticity through laser powder bed fusion (L-PBF) and [001] texture creation poses a challenge due to increased susceptibility to hot cracking in the resulting microstructure with columnar grains. This limitation restricts NiTi's application and contributes to material waste. To overcome this, we introduce...

High strain rate torsional response of maraging steel parts produced by laser powder bed fusion techniques: Deformation behavior and constitutive model

The deformation performance of maraging steel samples fabricated using the laser powder bed fusion technique was evaluated using the split Hopkinson torsion bar (SHTB) test. Thin-walled tubular maraging steel samples were deformed under dynamic torsional loading at strain rates of 260 s⁻¹ to 720 s⁻¹ using twist angles...

Additive manufacturing of functionally graded inconel 718: Effect of heat treatment and building orientation on microstructure and fatigue behaviour

This paper addresses the effect of the post-process heat treatments on the microstructure and fatigue crack growth behaviour of the functionally graded (FG) laser powder bed fusion (L-PBF) Inconel 718 (IN718) superalloy. Sets of samples were additively manufactured (AM) altering the process parameters, namely the laser power, the laser...

Effect of microstructure induced anisotropy on fatigue behaviour of functionally graded Inconel 718 fabricated by additive manufacturing

In this paper, the effect of microstructural anisotropy on the fatigue crack growth behaviour of the functionally graded Inconel 718 fabricated through laser powder bed fusion (L-PBF) is investigated. Different manufacturing parameters, including low and high laser powers, were used to produce a variety of non-graded (NG) and functionally...

Predictive analytical modelling and experimental validation of processing maps in additive manufacturing of nitinol alloys

Nitinol (NiTi) shape memory alloys fabricated by Laser Powder Bed Fusion (L-PBF) Additive Manufacturing (AM) have attracted much attention in recent years, as compared with conventional manufacturing processes it allows to produce Nitinol parts with high design complexity. Avoidance of defects during L-PBF is crucial for the production of...