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Robust interface and excellent as-built mechanical properties of Ti–6Al–4V fabricated through laser-aided additive manufacturing with powder and wire

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International Journal of Minerals,Metallurgy and Materials 2025年第1期32卷 154-168页

作者： Fei Weng Guijun Bi Youxiang Chew Shang Sui chaolin tan Zhenglin Du Jinlong Su Fern Lan Ng Key Laboratory for Liquid-Solid Structural Evolution and Processing of Materials Ministry of EducationShandong Engineering&Technology Research Center for Superhard MaterialSchool of Materials Science and EngineeringShandong UniversityJinan 250061China Institute of Intelligent Manufacturing Guangdong Academy of SciencesGuangzhou 510095China Singapore Institute of Manufacturing Technology 5 Cleantech Loop636732Singapore

The feasibility of manufacturing Ti-6Al-4V samples through a combination of laser-aided additive manufacturing with powder(LAAM_(p))and wire(LAAM_(w))was explored.A process study was first conducted to successfully circumvent defects in Ti-6Al-4V deposits for LAAM_(p) and LAAM_(w),*** the optimized process parameters,robust interfaces were achieved between powder/wire deposits and the forged substrate,as well as between powder and wire *** characterization results revealed the epitaxial prior β grains in the deposited Ti-6Al-4V,wherein the powder deposit was dominated by a finerα′microstructure and the wire deposit was characterized by lamellar α *** mechanisms of microstructure formation and correlation with mechanical behavior were analyzed and *** mechanical properties of the interfacial samples can meet the requirements of the relevant Aerospace Material Specifications(AMS 6932)even without post heat *** fracture occurred within the interfacial area,further suggesting the robust *** findings of this study highlighted the feasibility of combining LAAM_(p) and LAAM_(w) in the direct manufacturing of Ti-6Al-4V parts in accordance with the required dimensional resolution and deposition rate,together with sound strength and ductility balance in the as-built condition.

关键词： laser-aided additive manufacturing powder deposition wire deposition interfacial characteristic mechanical behavior

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4D printing for future manufacturing

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Science China Materials 2023年第11期66卷 4517-4518页

作者： chaolin tan Ji Zou Zhengyi Fu Singapore Institute of Manufacturing Technology(SIMTech) Agency for ScienceTechnology and Research(A*STAR)Singapore 636732Singapore State Key Laboratory of Advanced Technology for Materials Synthesis and Processing Wuhan University of TechnologyWuhan 430070China

Additive manufacturing(AM),also called three-dimensional(3D)printing,offers disruptive design freedom and manufacturing flexibility due to the layer-wise incremental formation manner of *** in AM techniques provide unique advantages and feasibilities for overcoming challenges arising from fabricating parts with complexities in geometry,materials,and properties.

关键词： printing properties freedom

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Study of the intrinsic mechanisms of nickel additive for grain refinement and strength enhancement of laser aided additively manufactured Ti–6Al–4V

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International Journal of Extreme Manufacturing 2022年第3期4卷 132-148页

作者： Shang Sui Youxiang Chew Fei Weng chaolin tan Zhenglin Du Guijun Bi Singapore Institute of Manufacturing Technology A∗STAR73 Nanyang Drive637662Singapore Institute of Intelligent Manufacturing GDASGuangzhou 510070People’s Republic of China

It is well-known that grain refiners can tailor the microstructure and enhance the mechanical properties of titanium alloys fabricated by additive manufacturing(AM). However, the intrinsic mechanisms of Ni addition on AM-built Ti–6Al–4V alloy is not well established. This limits its industrial applications. This work systematically investigated the influence of Ni additive on Ti–6Al–4V alloy fabricated by laser aided additive manufacturing(LAAM). The results showed that Ni addition yields three key effects on the microstructural evolution of LAAM-built Ti–6Al–4V alloy.(a) Ni additive remarkably refines the prior-β grains, which is due to the widened solidification range. As the Ni addition increased from 0 to 2.5 wt. %, the major-axis length and aspect ratio of the prior-β grains reduced from over 1500 μm and 7 to 97.7 μm and1.46, respectively.(b) Ni additive can discernibly induce the formation of globular α phase,which is attributed to the enhanced concentration gradient between the β and α phases. This is the driving force of globularization according to the termination mass transfer theory. The aspect ratio of the α laths decreased from 4.14 to 2.79 as the Ni addition increased from 0 to2.5 wt. %.(c) Ni as a well-known β-stabilizer and it can remarkably increase the volume fraction of β phase. Room-temperature tensile results demonstrated an increase in mechanical strength and an almost linearly decreasing elongation with increasing Ni addition. A modified mathematical model was used to quantitatively analyze the strengthening mechanism. It was evident from the results that the α lath phase and the solid solutes contribute the most to the overall yield strength of the LAAM-built Ti–6Al–4V–x Ni alloys in this work. Furthermore, the decrease in elongation with increasing Ni addition is due to the deterioration in deformability of the β phase caused by a large amount of solid-solution Ni atoms. These findings can accelerate the development of additively manufacture

关键词： Ni addition microstructure refinement laser aided additive manufacturing titanium alloys strengthening mechanism

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Additive manufacturing SiC-reinforced maraging steel: Parameter optimisation, microstructure and properties

Advanced Powder Materials

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Advanced Powder Materials 2023年第1期2卷 72-82页

作者： chaolin tan Wenyou Ma Cheng Deng Danli Zhang Kesong Zhou School of Mechanical and Automotive Engineering South China University of TechnologyGuangzhou 510640China Institute of New Materials Guangdong Academy of SciencesGuangzhou 510651China Singapore Institute of Manufacturing Technology 73 Nanyang Drive637662Singapore State Key Laboratory for Mechanical Behavior of Materials Xi'an Jiaotong UniversityXi'an 710049China

The unique deposition manner of additive manufacturing(AM)allows the near-net-shaping of components with multiple materials configurations and complex geometries,which sheds light on the process of high-performance metal matrix composites(MMCs).This work explores laser powder bed fusion(LPBF)AM of SiC-reinforced maraging steel MMCs to consolidate the merits of both ceramics and metal matrix for improving overall prop*** laser processing parameters were systematically optimised based on the density,roughness and hardness of the deposited *** effects of SiC content on the microstructures,mechanical properties,tribological performance,and wear resistance are *** particles are refined with uniform distribution in the metal matrix after laser *** highest tensile strength reaches 1611 MPa together with an elongation of about 10.1%with 3 vol%SiC *** tribological performance of MMCs is investigated by studying the coefficient of friction(COF),wear rate,and worn *** COF has been slightly reduced with the SiC addition,and the wear rate of MS reduced from 3.25×10^(-5) to 1.72×10^(-5)mm^(3)/Nm with the 12 vol% SiC *** underlying wear mechanisms are also ***,the corrosion behaviour of MMCs is also investigated;the addition of SiC(≥6 vol%)has improved the corrosion properties of the matrix.

关键词： Laser powder bed fusion Metal matrix composite Maraging steel Wear resistance Corrosion behaviour

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Additive manufacturing of steel–copper functionally graded material with ultrahigh bonding strength

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Journal of Materials Science & Technology 2021年第13期72卷 217-222页

作者： chaolin tan Youxiang Chew Guijun Bi Di Wang Wenyou Ma Yongqiang Yang Kesong Zhou School of Mechanical and Automotive Engineering South China University of TechnologyGuangzhou 510640China National Engineering Laboratory for Modern Materials Surface Engineering Technology Institute of New MaterialsGuangdong Academy of SciencesGuangzhou 510651China Singapore Institute of Manufacturing Technology A*STAR73 Nanyang Drive637662Singapore

Additive manufacturing enables processing of functionally graded materials(FGMs)with flexible spatial design and high bonding strength.A steel-copper FGM with high interfacial strength was developed using laser powder bed fusion(LPBF).The effect of laser process parameters on interfacial defects was evaluated by X-ray tomography,which indicates a low porosity level of 0.042%***/fine dendritic grains in the interface are incited by high cooling rates,which facilitates interface *** mechanical tests evaluate the bonding reliability of interface;and the fatigue tests further substantiate the ultrahigh bonding strength in FGMs,which is superior to traditional manufacturing *** of the high interfacial bond strength were also discussed.

关键词： Laser powder bed fusion Steel–copper multi-materials Fatigue Functionally graded materials Bonding strength

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Review on laser directed energy deposited aluminum alloys

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International Journal of Extreme Manufacturing 2024年第2期6卷 84-131页

作者： Tian-Shu Liu Peng Chen Feng Qiu Hong-Yu Yang Nicholas tan Yew Jin Youxiang Chew Di Wang Ruidi Li Qi-Chuan Jiang chaolin tan Singapore Institute of Manufacturing Technology(SIMTech) Agency for ScienceTechnology and Research(A∗STAR)5 Cleantech LoopSingapore 636732Singapore State Key Laboratory of Automotive Simulation and Control Jilin UniversityChangchun 130025People’s Republic of China Key Laboratory of Automobile Materials Ministry of Education and Department of Materials Science and EngineeringJilin UniversityChangchun 130025People’s Republic of China School of Mechanical&Automotive Engineering South China University of TechnologyGuangzhou 510640People’s Republic of China State Key Laboratory of Powder Metallurgy Central South UniversityChangsha 410083People’s Republic of China

Lightweight aluminum(Al)alloys have been widely used in frontier fields like aerospace and automotive industries,which attracts great interest in additive manufacturing(AM)to process high-value Al *** a mainstream AM technique,laser-directed energy deposition(LDED)shows good scalability to meet the requirements for large-format component manufacturing and ***,LDED Al alloys are highly challenging due to their inherent poor printability(*** laser absorption,high oxidation sensitivity and cracking tendency).To further promote the development of LDED high-performance Al alloys,this review offers a deep understanding of the challenges and strategies to improve printability in LDED Al *** porosity,cracking,distortion,inclusions,element evaporation and resultant inferior mechanical properties(worse than laser powder bed fusion)are the key challenges in LDED Al *** parameter optimizations,in-situ alloy design,reinforcing particle addition and field assistance are the efficient approaches to improving the printability and performance of LDED Al *** underlying correlations between processes,alloy innovation,characteristic microstructures,and achievable performances in LDED Al alloys are *** benchmark mechanical properties and primary strengthening mechanism of LDED Al alloys are *** review aims to provide a critical and in-depth evaluation of current progress in LDED Al *** opportunities and perspectives in LDED high-performance Al alloys are also outlined.

关键词： additive manufacturing laser directed energy deposition(LDED) aluminum alloys printability aluminum matrix composite auxiliary fields mechanical properties

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Effect of Bionic Unit Shapes on Solid Particle Erosion Resistance of ZrO2-7wt%Y2O3 Thermal Barrier Coatings Processed by Laser

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Journal of Bionic Engineering 2018年第3期15卷 545-557页

作者： Panpan Zhang Fuhai Li Xiaofeng Zhang Zhihui Zhang chaolin tan Luquan Ren Yueliang Wang Wenyou Ma Min Liu The Key Laboratory of Bionic Engineering (Ministry of Education China) Jilin University 5988 Renmin Street Changchun 130022 China Guangdong Institute of New Materials National Engineering Laboratory for Modern Materials Surface Engineering Technology the Key Lab of Guangdong for Modern Surface Engineering Technology Guangzhou 510651 China The State Key Laboratory of Automotive Simulation and Control Jilin University 5988 Renmin Street Changchun 130022 China

Inspired by the coupling phenomena in biological systems, to improve the solid particle erosion resistance of Thermal Barrier Coatings （TBCs）, different kinds of bionic units were made on the coating surfaces using Bionic Coupled Laser Remelting （BCLR） process. The NiCoCrAlYTa/ZrO2-7wt%Y2O3 double-layer structured TBCs were prepared by air plasma spraying. The microstructure, microhardness and phase composition of the as-sprayed and bionic specimens were examined. The solid particle erosion behaviors of bionic specimens as function of bionic unit shape were investigated. The results indicated that the bionic specimens had better erosion resistance than the as-sprayed specimen. The specimen with striation and grid bionic units had the better erosion resistance, while the dot showed the worse. The bionic units were characterized by the dense columnar crystal structure and the high hardness, which are the main reasons for improving the erosion resistance. Under the synergistic action of the shear stress and normal stress on the protrusive coating surface, the erosion failure of the as-sprayed TBCs was proved to be the fracture and spallation of the splats. By contrast, the spallation of segmented bionic unit occurred in the overlapping area between the adjacent laser irradiation, and the erosive unit surface presented the clear and deep furrows, which revealed that the erosion failure mechanism of bionic TBCs was dominated by brittle and some ductile erosion. These results showed more opportunities for bionic application in improving the solid particle erosion resistance of components in the windy and sandy environment.

关键词： bionic thermal barrier coatings erosion resistance laser

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Effect of cyclic heat treatment on microstructure and mechanical properties of laser aided additive manufacturing Ti-6Al-2Sn-4Zr-2Mo alloy

Advanced Powder Materials

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Advanced Powder Materials 2022年第1期1卷 59-66页

作者： Shang Sui Youxiang Chew Zhiwei Hao Fei Weng chaolin tan Zhenglin Du Guijun Bi Singapore Institute of Manufacturing Technology A∗STAR73 Nanyang Drive637662Singapore State Key Laboratory of Solidification Processing Northwestern Polytechnical University127 West Youyi RoadBeilin DistrictXi'an Shaanxi710072China Key Laboratory of Metal High Performance Additive Manufacturing and Innovative Design MIIT ChinaNorthwestern Polytechnical University127 West Youyi RoadBeilin DistrictXi'an Shaanxi710072China

Globularαphases can significantly improve the ductility of titanium *** heat treatment(CHT)has been proved to be an effective way to induce the formation of globularαphases inα+βtitanium alloy Ti-6Al-4V fabricated by laser aided additive manufacturing(LAAM).However,there is no prior research reporting methods for obtaining globularαphases in LAAM-built near-αtitanium *** work investigated the cyclic heat treatment(CHT)procedures suitable for the LAAM-built near-αtitanium alloy Ti-6Al-2Sn-4Zr-2Mo(Ti6242)to attain the globularα*** results show that 980℃ is the most suitable upper temperature limit for ***,it is difficult to achieve a high volume fraction of the globularαphases in the LAAM-built Ti6242 alloys through CHT,which is ascribed to the low composition gradient caused by moreα-stabilizing elements and fewerβ-stabilizing *** as-built sample demonstrated elongation of 6.3%,which is lower than the AMS 4919J standard(elongation≥10%).After 980℃ CHT and 980℃ CHT with solution heat-treatment,the formation of the globularαphases significantly increased the elongation to 13.5%and 12.9%,*** the mechanical strength is reduced after heat-treatment,the room-temperature tensile properties still exceed the AMS 4919J *** examination showed that the as-built sample exhibited a mixed brittle and ductile fracture behavior,while the 980℃ CHT and 980℃ CHT with solution heat-treated samples displayed ductile fracture.

关键词： Cyclic heat treatment Globularαphase Ti6242 alloy Laser aided additive manufacturing Room-temperature tensile properties

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Mechanical property and biological behaviour of additive manufactured TiNi functionally graded lattice structure

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International Journal of Extreme Manufacturing 2022年第4期4卷 207-213页

作者： chaolin tan Cheng Deng Sheng Li Alessandro Abena Parastoo Jamshidi Khamis Essa Likang Wu Guohua Xu Moataz M Attallah Jia Liu School of Metallurgy&Materials University of BirminghamBirmingham B152TTUnited Kingdom Department of Orthopedic Surgery Second Affiliated Hospital of Naval Medical UniversityShanghai 200003People's Republic of China School of Engineering University of BirminghamBirmingham B152TTUnited Kingdom School of Mechanical&Automotive Engineering South China University of TechnologyGuangzhou 510640People's Republic of China

Bio-inspired porous metallic scaffolds have tremendous potential to be used as artificial bone *** this work,a radially graded lattice structure (RGLS),which mimics the structures of natural human bones,was designed and processed by laser powder bed fusion of martensitic Ti-rich TiNi *** asymmetric tension-compression behaviour,where the compressive strength is significantly higher than the tensile strength,is observed in this Ti-rich TiNi material,which echoes the mechanical behaviour of *** morphologies,mechanical properties,deformation behaviour,and biological compatibility of RGLS samples were characterised and compared with those in the uniform lattice *** the uniform and RGLS samples achieve a relative density higher than 99%.The graded porosities and pore sizes in the RGLS range from 40%-80% and 330-805 µm,respectively,from the centre to the *** chemical etching has significantly removed the harmful partially-melted residual powder particles on the lattice *** compressive yield strength of RGLS is 71.5 MPa,much higher than that of the uniform sample (46.5 MPa),despite having a similar relative density of about 46%.The calculated Gibson-Ashby equation and the deformation behaviour simulation by finite element suggest that the dense outer regions with high load-bearing capability could sustain high applied stress,improving the overall strength of RGLS *** cell proliferation study suggests better biological compatibility of the RGLS than the uniform *** findings highlight a novel strategy to improve the performance of additively manufactured artificial implants by bio-inspiration.

关键词： additive manufacturing bio-inspired graded lattice mechanical properties biological compatibility

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Recent innovations in laser additive manufacturing of titanium alloys

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International Journal of Extreme Manufacturing 2024年第3期6卷 2-37页

作者： Jinlong Su Fulin Jiang Jie Teng Lequn Chen Ming Yan Guillermo Requena Lai-Chang Zhang Y Morris Wang Ilya V Okulov Hongmei Zhu chaolin tan College of Materials Science and Engineering Hunan UniversityChangsha 410082People’s Republic of China Singapore Institute of Manufacturing Technology(SIM Tech) Agency for ScienceTechnology and Research(A∗STAR)5 Cleantech LoopSingapore 636732Singapore Department of Materials Science and Engineering Southern University of Science and TechnologyShenzhen 518055People’s Republic of China Institute of Materials Research German Aerospace Center(DLR)Linder Höhe51147 CologneGermany Centre for Advanced Materials and Manufacturing Edith Cowan University270 Joondalup DriveJoondalupPerthWestern Australia 6027Australia Department of Materials Science and Engineering University of CaliforniaLos AngelesCA 900095United States of America Leibniz Institute for Materials Engineering-IWT Badgasteiner Str.328359 BremenGermany Faculty of Production Engineering University of BremenBadgasteiner Str.128359 BremenGermany Key Laboratory of Hunan Province of Equipment Safety Service Technology under Extreme Environment University of South ChinaHengyangPeople’s Republic of China RWTH Aachen University Metallic Structures and Materials Systems for Aerospace EngineeringD-52062 AachenGermany

Titanium(Ti)alloys are widely used in high-tech fields like aerospace and biomedical *** additive manufacturing(LAM),as an innovative technology,is the key driver for the development of Ti *** the significant advancements in LAM of Ti alloys,there remain challenges that need further research and development *** recap the potential of LAM high-performance Ti alloy,this article systematically reviews LAM Ti alloys with up-to-date information on process,materials,and *** feasible solutions to advance LAM Ti alloys are reviewed,including intelligent process parameters optimization,LAM process innovation with auxiliary fields and novel Ti alloys customization for *** auxiliary energy fields(***,acoustic,mechanical deformation and magnetic fields)can affect the melt pool dynamics and solidification behaviour during LAM of Ti alloys,altering microstructures and mechanical *** kinds of novel Ti alloys customized for LAM,like peritecticα-Ti,eutectoid(α+β)-Ti,hybrid(α+β)-Ti,isomorphousβ-Ti and eutecticβ-Ti alloys are reviewed in ***,machine learning in accelerating the LAM process optimization and new materials development is also *** review summarizes the material properties and performance envelops and benchmarks the research achievements in LAM of Ti *** addition,the perspectives and further trends in LAM of Ti alloys are also highlighted.

关键词： additive manufacturing titanium alloys auxiliary field machine learning aerospace materials lightweight materials novel alloys

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