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Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

Their high strength-to-weight ratio, good corrosion resistance and excellent thermal and electrical conductivity have exponentially increased the interest in aluminium alloys in the context of laser-based powder bed fusion (PBF-LB/M) production. Although Al-based alloys are the third most investigat...

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Autores principales: Martucci, Alessandra, Aversa, Alberta, Lombardi, Mariangela
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9921184/
https://www.ncbi.nlm.nih.gov/pubmed/36770091
http://dx.doi.org/10.3390/ma16031084
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author Martucci, Alessandra
Aversa, Alberta
Lombardi, Mariangela
author_facet Martucci, Alessandra
Aversa, Alberta
Lombardi, Mariangela
author_sort Martucci, Alessandra
collection PubMed
description Their high strength-to-weight ratio, good corrosion resistance and excellent thermal and electrical conductivity have exponentially increased the interest in aluminium alloys in the context of laser-based powder bed fusion (PBF-LB/M) production. Although Al-based alloys are the third most investigated category of alloys in the literature and the second most used in industry, their processing by PBF-LB/M is often hampered by their considerable solidification shrinkage, tendency to oxidation, high laser reflectivity and poor powder flowability. For these reasons, high-strength Al-based alloys traditionally processed by conventional procedures have often proved to be unprintable with additive technology, so the design and development of new tailored Al-based alloys for PBF-LB/M production is necessary. The aim of the present work is to explore all the challenges encountered before, during and after the PBF-LB/M processing of Al-based alloys, in order to critically analyse the solutions proposed in the literature and suggest new approaches for addressing unsolved problems. The analysis covers the critical aspects in the literature as well as industrial needs, industrial patents published to date and possible future developments in the additive market.
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spelling pubmed-99211842023-02-12 Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review Martucci, Alessandra Aversa, Alberta Lombardi, Mariangela Materials (Basel) Review Their high strength-to-weight ratio, good corrosion resistance and excellent thermal and electrical conductivity have exponentially increased the interest in aluminium alloys in the context of laser-based powder bed fusion (PBF-LB/M) production. Although Al-based alloys are the third most investigated category of alloys in the literature and the second most used in industry, their processing by PBF-LB/M is often hampered by their considerable solidification shrinkage, tendency to oxidation, high laser reflectivity and poor powder flowability. For these reasons, high-strength Al-based alloys traditionally processed by conventional procedures have often proved to be unprintable with additive technology, so the design and development of new tailored Al-based alloys for PBF-LB/M production is necessary. The aim of the present work is to explore all the challenges encountered before, during and after the PBF-LB/M processing of Al-based alloys, in order to critically analyse the solutions proposed in the literature and suggest new approaches for addressing unsolved problems. The analysis covers the critical aspects in the literature as well as industrial needs, industrial patents published to date and possible future developments in the additive market. MDPI 2023-01-26 /pmc/articles/PMC9921184/ /pubmed/36770091 http://dx.doi.org/10.3390/ma16031084 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Review
Martucci, Alessandra
Aversa, Alberta
Lombardi, Mariangela
Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review
title Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review
title_full Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review
title_fullStr Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review
title_full_unstemmed Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review
title_short Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review
title_sort ongoing challenges of laser-based powder bed fusion processing of al alloys and potential solutions from the literature—a review
topic Review
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9921184/
https://www.ncbi.nlm.nih.gov/pubmed/36770091
http://dx.doi.org/10.3390/ma16031084
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