Research Progress on Additive Manufacturing of Metallic Heterogeneous Materials

doi:10.3901/JME.2021.01.186

Abstract

Abstract: New requirements for the functionality of materials are raised on the conditions of extremely complex working conditions. Compared with traditional manufacturing technology, additive manufacturing technology of metal heterogeneous materials has greater advantages in the manufacture of heterogeneous material parts. It has broad application prospects in many areas, such as aerospace, biomedical and automotive industries, and can meet these areas’ demand for high performance and multifunctionality of components. Based on the research progress of metal heterogeneous material additive manufacturing technology in recent years, the research status and technical characteristics of arc, electron beam and laser additive manufacturing technology on heterogeneous materials are reviewed. In addition, based on the team’s research on heterogeneous material metal additive manufacturing equipment, material technology and interface defects, the key problems and applications of metal heterogeneous material additive manufacturing technology are summarized, and its development trend are prospected.

Key words: heterogeneous material, additive manufacturing, multifunctional requirements, interface performance

CLC Number:

TH16

WANG Di, DENG Guowei, YANG Yongqiang, CHEN Jie, WU Weihui, ZHANG Mingkang. Research Progress on Additive Manufacturing of Metallic Heterogeneous Materials[J]. Journal of Mechanical Engineering, 2021, 57(1): 186-198.

References

[1] BHAVAR V,KATTIRE P,THAKARE S,et al. A review on functionally gradient materials (FGMs) and their applications[C]//IOP Conference Series:Materials Science and Engineering. IOP Publishing Ltd,2017,229:12021.
[2] 李永兵,马运五,楼铭,等. 轻量化多材料汽车车身连接技术进展[J]. 机械工程学报,2016,52(24):1-23. LI Yongbing,MA Yunwu,LOU Ming,et al. Advances in welding and joining processes of multi-material lightweight car body[J]. Journal of Mechanical Engineering,2016,52(24):1-23.
[3] BARTOLOMEU F,ABREU C S,MOURA C G,et al. Ti6Al4V-PEEK multi-material structures-design,fabrication and tribological characterization focused on orthopedic implants[J]. Tribology International,2019,131:672-678.
[4] 吴伟辉,杨永强,毛桂生,等. 激光选区熔化自由制造异质材料零件[J]. 光学精密工程,2019,27(3):517-526. WU Weihui,YANG Yongqiang,MAO Guisheng,et al. Free manufacturing of heterogeneous materials part by selective laser melting[J]. Optics and Precision Engineering,2019,27(3):517-526.
[5] WANG P,LAO C S,CHEN Z W,et al. Microstructure and mechanical properties of Al-12Si and Al-3.5Cu-1.5Mg-1Si bimetal fabricated by selective laser melting[J]. Journal of Materials Science & Technology,2020,36:18-26.
[6] 王泽力,张元彬,史传伟. 丝材增材制造技术研究现状与展望[J]. 热加工工艺,2019,48(3):6-10,5. WANG Zeli,ZHANG Yuanbin,SHI Chuanwei. Research status and prospect of wire additive manufacturing technology[J]. Hot Working Technology, 2019,48(3):6-10,5.
[7] 王世杰,王海东,罗锋. 基于电弧的金属增材制造技术研究现状[J]. 金属加工(热加工),2018(1):19-22. WANG Shijie,WANG Haidong,LUO Feng. Research status of arc-based metal additive manufacturing technology[J]. MW Metal Forming,2018(1):19-22.
[8] LIU L,ZHUANG Z,LIU F,et al. Additive manufacturing of steel-bronze bimetal by shaped metal deposition:Interface characteristics and tensile properties[J]. The International Journal of Advanced Manufacturing Technology. 2013,69(9-12):2131-2137.
[9] SHEN C,SHEN C,PAN Z,et al. Fabrication of Fe-FeAl functionally graded material using the wire-arc additive manufacturing process[J]. Metallurgical and Materials Transactions B,2016,47(1):763-772.
[10] 刘志森,薛丁琪,韩绍华,等. 基于CMT焊接的双金属电弧增材成形件的组织和力学性能[J]. 热加工工艺. 2017,46(17):184-186. LIU Zhiseng,XUE Dingqi,HAN Shaohua,et al. Microstructure and mechanical properties of double metal arc additive forming part based on CMT welding[J]. Hot Working Technology,2017,46(17):184-186.
[11] 苗玉刚,李春旺,赵慧慧,等. 铜/钢复合接头旁路热丝等离子弧增材特性分析[J]. 焊接学报. 2019,40(5):95-99. MIAO Yugang,LI Chunwang,ZHAO Huihui,et al. Characteristic analysis of copper/steel composite joint bypass-current wire-heating PAW on additive manufacturing[J]. Transactions of the China Welding Institution,2019,40(5):95-99.
[12] TREUTLER K,KAMPER S,LEICHER M,et al. Multi-material design in welding arc additive manufacturing[J]. Metals,2019,9(7):809.
[13] 郭一飞. 机器人CMT增材制造高氮钢-316L多层结构试验研究[D]. 南京:南京理工大学,2018. GUO Yifei. Experimental research on multilayer structure of high nitrogen steel-316L made by robot CMT additive manufacturing[D]. Nanjing:Nanjing University of Science and Technology,2018.
[14] TERRAZAS C A,GAYTAN S M,RODRIGUEZ E,et al. Multi-material metallic structure fabrication using electron beam melting[J]. The International Journal of Advanced Manufacturing Technology,2014,71(1):33-45.
[15] GUO Chao,GE Wenjun,LIN Feng. Dual-material electron beam selective melting:Hardware development and validation studies[J]. Engineering,2015,1(1):249-262.
[16] HINOJOS A,MIRELES J,REICHARDT A,et al. Joining of inconel 718 and 316 stainless steel using electron beam melting additive manufacturing technology[J]. Materials & Design,2016,94:17-27.
[17] GURIANOV D A,KALASHNIKOV K N,OSIPOVICH K S,et al. Obtaining the bimetallic composition by the electron beam freeform fabrication[C]//IOP Conference Series:Materials Science and Engineering. IOP Publishing Ltd,2019,597:12043.
[18] OSIPOVICH K S,KALASHNIKOV K N,VORONTSOV A V. Alloying effect of Ti-6Al-4V on composite of 321 stainless steel fabricated by electron beam additive manufacturing[C]//IOP Conference Series:Materials Science and Engineering,IOP Publishing Ltd,2019,537:22075.
[19] QIAN T,LIU D,TIAN X,et al. Microstructure of TA2/TA15 graded structural material by laser additive manufacturing process[J]. Transactions of Nonferrous Metals Society of China,2014,24(9):2729-2736.
[20] ZHANG Y,BANDYOPADHYAY A. Direct fabrication of compositionally graded Ti-Al₂O₃ multi-material structures using laser engineered net shaping[J]. Additive Manufacturing,2018,21:104-111.
[21] HEER B,BANDYOPADHYAY A. Compositionally graded magnetic-nonmagnetic bimetallic structure using laser engineered net shaping[J]. Materials Letters,2018,216:16-19.
[22] ONUIKE B,HEER B,BANDYOPADHYAY A. Additive manufacturing of Inconel 718-Copper alloy bimetallic structure using laser engineered net shaping (LENS^TM)[J]. Additive Manufacturing,2018,21:133-140.
[23] ONUIKE B,BANDYOPADHYAY A. Additive manufacturing of Inconel 718- Ti6Al4V bimetallic structures[J]. Additive Manufacturing,2018,22:844-851.
[24] DEMIR A G,PREVITALI B. Multi-material selective laser melting of Fe/Al-12Si components[J]. Manufacturing Letters,2017,11:8-11.
[25] WEI C,LI L,ZHANG X,et al. 3D printing of multiple metallic materials via modified selective laser melting[J]. CIRP Annals,2018,67(1):245-248.
[26] WEI C,GU H,SUN Z,et al. Ultrasonic material dispensing-based selective laser melting for 3D printing of metallic components and the effect of powder compression[J]. Additive Manufacturing,2019,29:100818.
[27] ZHANG X,CHUEH Y,WEI C,et al. Additive manufacturing of three-dimensional metal-glass functionally gradient material components by laser powder bed fusion with in situ powder mixing[J]. Additive Manufacturing,2020,33:101113.
[28] 刘帅,王阳,刘常升. 激光熔化沉积技术在制备梯度功能材料中的应用[J]. 航空制造技术. 2018,61(17):47-56. LIU Shuai,WANG Yang,LIU Changsheng. Application of laser melt deposition technique in preparation of functionally gradient materials[J]. Aeronautical Manufacturing Technology,2018,61(17):47-56.
[29] 吴伟辉,杨永强,毛桂生,等. 异质材料零件SLM增材制造系统设计与实现[J]. 制造技术与机床,2019(10):32-37. WU Weihui,YANG Yongqiang,MAO Guisheng,et al. Design and implementation of SLM system for additive manufacturing of heterogeneous material parts[J]. Manufacturing Technology & Machine Tool, 2019(10):32-37.
[30] MEI X,WANG X,PENG Y,et al. Interfacial characterization and mechanical properties of 316L stainless steel/inconel 718 manufactured by selective laser melting[J]. Materials Science and Engineering:A,2019,758:185-191.
[31] CHEN J,YANG Y,SONG C,et al. Interfacial microstructure and mechanical properties of 316L/CuSn10 multi-material bimetallic structure fabricated by selective laser melting[J]. Materials Science and Engineering:A,2019,752:75-85.
[32] LIU Z H,ZHANG D Q,SING S L,et al. Interfacial characterization of SLM parts in multi-material processing:Metallurgical diffusion between 316L stainless steel and C18400 copper alloy[J]. Materials Characterization,2014,94:116-125.
[33] CHEN C,GU D,DAI D,et al. Laser additive manufacturing of layered TiB2/Ti6Al4V multi-material parts:Understanding thermal behavior evolution[J]. Optics & Laser Technology,2019,119:105666.
[34] DAI D,GU D,POPRAWE R,et al. Influence of additive multilayer feature on thermodynamics,stress and microstructure development during laser 3D printing of aluminum-based material[J]. Science Bulletin,2017,62(11):779-787.
[35] WANG R,GU D,XI L,et al. Selective laser melted TiB2/Ti6Al4V graded materials and first-principle calculations[J]. Materials Letters,2019,254:33-36.
[36] 吴静雯. 基于三维打印工艺的多材料零件数字化处理研究[D]. 南京:南京师范大学,2016. WU Jingwen. Research on digital processing of multi-material parts based on 3D printing process[D]. Nanjing:Nanjing Normal University,2016.
[37] 张争艳. 异质多材料零件快速成型关键技术研究[D]. 武汉:武汉理工大学. 2014. ZHANG Zhengyan. Research of key technologies on heterogeneous and multiple materials rapid prototyping[D]. Wuhan:Wuhan University of Technology. 2014.
[38] 施建平,杨继全,王兴松. 多材料零件3D打印技术现状及趋势[J]. 机械设计与制造工程,2017,46(2):11-17. SHI Jianping,YANG Jiquan,WANG Xingsong. Status and trend of 3D printing technology for heterogeneous objects[J]. Machine Design and Manufacturing Engineering,2017,46(2):11-17.
[39] 祝小伟,王从军. 一种新的面向多材料增材制造的文件格式[J]. 现代制造工程,2017(10):30-34. ZHU Xiaowei,WANG Congjun. A new file format for multiple material additive manufacturing[J]. Modern Manufacturing Engineering,2017(10):30-34.
[40] KOOPMANN J,VOIGT J,NIENDORF T. Additive manufacturing of a steel-ceramic multi-material by selective laser melting[J]. Metallurgical and Materials Transactions B,2019,50(2):1042-1051.
[41] SING S L,LAM L P,ZHANG D Q,et al. Interfacial characterization of SLM parts in multi-material processing:Intermetallic phase formation between AlSi10Mg and C18400 copper alloy[J]. Materials Characterization,2015,107:220-227.
[42] BOBBIO L D,OTIS R A,BORGONIA J P,et al. Additive manufacturing of a functionally graded material from Ti-6Al-4V to Invar:Experimental characterization and thermodynamic calculations[J]. Acta Materialia,2017,127:133-142.
[43] TOMASHCHUK I,SALLAMAND P,CICALA E,et al. Direct keyhole laser welding of aluminum alloy AA5754 to titanium alloy Ti6Al4V[J]. Journal of Materials Processing Technology,2015,217:96-104.
[44] WEI C,SUN Z,CHEN Q,et al. Additive manufacturing of horizontal and 3D functionally graded 316L/Cu10Sn components via multiple material selective laser melting[J]. Journal of Manufacturing Science and Engineering-Transactions of the ASME,2019,141(8).
[45] WEI C,SUN Z,CHEN Q,et al. An integrated dual ultrasonic selective powder dispensing platform for three-dimensional printing of multiple material metal/glass objects in selective laser melting[J]. Journal of Manufacturing Science and Engineering-Transactions of the ASME,2019,141(8).
[46] ZHANG M,YANG Y,WANG D,et al. Microstructure and mechanical properties of CuSn/18Ni300 bimetallic porous structures manufactured by selective laser melting[J]. Materials & Design,2019,165:107583.
[47] 高晓霞,姜晓红,田东艳. 功能梯度材料研究的进展综述[J]. 山西建筑,2006,5:143-144. GAO Xiaoxia,JIANG Xiaohong,TIAN Dongyan. Summary of research progress of functionally graded material[J]. Shanxi Architecture,2006,5:143-144.
[48] NING F,HU Y,CONG W. Microstructure and mechanical property of TiB reinforced Ti matrix composites fabricated by ultrasonic vibration-assisted laser engineered net shaping[J]. Rapid Prototyping Journal,2019,25(3):581-591.
[49] YIN S,YAN X,CHEN C,et al. Hybrid additive manufacturing of Al-Ti6Al4V functionally graded materials with selective laser melting and cold spraying[J]. Journal of Materials Processing Technology,2018,255:650-655.
[50] 招润焯,丁东红,王凯,等. 金属增减材混合制造研究进展[J]. 电焊机,2019,49(7):66-77. ZHAO Runzhuo,DING Donghong,WANG Kai,et al. Research progress of metal additive and subtractive hybrid manufacturing technology[J]. Electric Welding Machine,2019,49(7):66-77.