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The great variability of the additively manufactured quality is becoming a major challenge to limit its wide application. Here, we combine the high-throughput molecular dynamics simulations with the artificial neural network to search for the high surface quality and damage minimization of the selective laser melted (SLMed) FeCrNi multi-principal-element alloy (MPEA), based on the complex microstructure obtained from experiment characterization. By adjusting the laser scanning speed and laser power density, a large amount of data related to the surface roughness, dislocation characteristics, and residual stress in the SLMed MPEAs is obtained for optimizing the SLM process. Atomic simulation results show that there are various degrees of Cr segregation under different processing parameters, which leads to the uncertainty of residual stress distribution and dislocation characteristics. Thus, the surface roughness and subsurface damage is highly sensitive to the SLM parameters. According to the training results of the artificial neural network, the laser scanning speed plays a more key role in regulating the surface integrity and subsurface damage in the SLMed MPEAs. The overall prediction results exhibit that the relatively slow laser scanning speed effectively reduces the residual stress. Importantly, a complex relationship between the SLMed parameters and properties is built. The current work provides a predictive recommendation to optimize the quality and process design of the SLMed MPEAs with high surface integrity and low subsurface damage. • High-throughput molecular dynamics simulations and the artificial neural network are combined. • Effect of the scanning speed, and laser power density on surface integrity of the SLMed MEPA is systematically analyzed. • A extremely complex relationship between the SLMed parameters and surface quality is quantitatively built. • Considering different weight coefficients of performance, the selection strategy of processing parameters is determined. [ABSTRACT FROM AUTHOR]

Additive/subtractive hybrid manufacturing technology is a new technology that combines product design, software control, and additive manufacturing (AM) with subtractive technology, which can realize the metallurgical bonding of dissimilar materials. In this study, hybrid parts made of two materials were fabricated by depositing CuCrZr on a 316 L stainless steel substrate by selective laser melting (SLM) technology. The microstructure and mechanical properties of the SLM-ed CuCrZr, 316 L matrix components and the 316 L/CuCrZr interface were studied. The microstructure of SLM-ed CuCrZr consisted of elongated columnar crystals that developed along the building direction, and the 316 L matrix material was characterised by large equiaxed grains. After the 316 L substrate was polished, there were no macroscopic cracks and only a few pores at the interface of 316 L/CuCrZr, and good metallurgical bonding was achieved. The complex and uneven metal flow occurred inside the molten pool because of the Marangoni effect under the action of the laser, resulting in drastic changes in the grain size at the interface. • CuCrZr alloy was fabricated by SLM on the 316 L substrate to achieve hybrid manufacturing. • Substrate surface state can influence interface of 316 L/CuCrZr. • Dendritic microcracks and pores are the main defects at the interface. • Difference in physical properties of materials and stress caused cracks. [ABSTRACT FROM AUTHOR]

Dynamic mechanical properties of the selected laser melting (SLM)-NiCrFeCoMo 0.2 high-entropy alloy (HEA) are further improved by controlling the molten pool structure and the generation of σ-phase precipitation particles. In this study, a split Hopkinson pressure bar (SHPB) was used for testing the dynamical mechanical properties of the quenched SLM-NiCrFeCoMo 0.2 HEA specimens. Microstructure and volume fraction of the σ precipitates were characterized by X-ray diffractometry (XRD), scanning electron microscope (SEM), transmission electron microscope (TEM), and the small angle neutron scattering (SANS) technique. After heating to 800 ℃, holding for 8 h and water quenching, the molten pool boundary of the SLM-NiCrFeCoMo 0.2 HEA disappear, and the ultimate compressive strength and the impact energy of specimens reach 1970 MPa and of 217.45 MJ·m−3, respectively. Due to the segregation of Mo elements in the molten-pool boundary of the as-build SLM-NiCrFeCoMo 0.2 HEA, more σ precipitates tend to form at the residual molten pool boundary of the quenched SLM-NiCrFeCoMo 0.2 HEA. The σ precipitates play key role in strengthening of the SLM-NiCrFeCoMo 0.2 HEA. • Annealed SLM- NiCrFeCoMo 0.2 HEA has larger ultimate compressive strength and the impact energy. • Lots of σ precipitates generate at the residual molten pool boundary. • Small angle neutron scattering technique is used to analyze the volume fraction of σ precipitates. • The σ precipitates play key role in strengthening of the SLM-NiCrFeCoMo 0.2 HEA. [ABSTRACT FROM AUTHOR]

Abstract Inconel 718 (IN718) superalloy has been fabricated by selective laser melting (SLM) technology, and the effects of the solution and double aging treatment on the microstructures and mechanical properties of the alloy have been studied. Under the same aging condition, the hardness of the IN718 superalloy first increased and then decreased with the increasing of the solution temperature. When the solution temperature was 980 °C, the average microhardness of the alloy was increased to 502 HV 0.2 , with 17.56% increase. With the solution temperature increasing, more short-rod δ phase (Ni 3 Nb) was precipitated at the grain boundaries and distributed homogeneously, and the γ′′ phase (Ni 3 Nb) and the γ′ phase (Ni 3 (Al, Ti)) were formed. The δ phase (Ni 3 Nb) can pin grain boundary, inhibit the grain growth and improve the mechanical properties. In addition, the corrosion resistance of the alloy decreased after heat treatment. After heat treatments, the formation of the second phase subsequently increased the number of corrosion microbatteries and reduced the anticorrosive ability of the alloy. Highlights • The anticorrosive ability of IN718 alloys decreased after heat treament. • The second phase improve the property, but decrease the anticorrosive ability. • Giving good comprehensive mechanical properties after heat treament. [ABSTRACT FROM AUTHOR]

To improve the dynamic mechanical properties of the selective laser melting (SLM)-NiCrFeCoMo 0.2 high entropy alloy (HEA), dynamic impact experiments were carried out on this alloy with different characteristic molten pools. Melt pool structures of different special sizes can be obtained by adjusting the laser power and scanning speed during the SLM process. In this work, the split-Hopkinson pressure bar (SHPB) is used to conduct dynamic impact on the SLM-NiCrFeCoMo 0.2 HEA samples with different molten pool size. The X-ray diffractometer (XRD), the scanning electron microscope (SEM), the electron probes micro-analyzer (EPMA) and the transmission electron microscope (TEM) were used to characterize the microstructure and deformation characteristics of the of the molten pool. The SLM-NiCrFeCoMo 0.2 HEA shows high impact energy absorption density and compressive strength at high strain rate. Volume energy density (VED) refers to the power delivered by the laser per unit volume of material during a SLM process, which can affect the size of the molten pool formed. Mo-rich σ phase precipitations are distributed near the molten pool boundary. In the cooling stage of the SLM process, the center of the molten pool has a faster cooling rate than the molten pool boundary, so area near the boundary stays in the temperature range where the precipitation occurs for a longer time, which is the reason why the precipitates are concentrated near the boundary. The precipitation strengthening in the SLM-NiCrFeCoMo 0.2 HEA is considered by measuring the relationship between the molten pool structure and the precipitation distribution, considering the material as a composite of the precipitation dense region (PDR) and the precipitation free region (PFR), and the strength contribution of precipitation is estimated by mixing rules. [Display omitted] • Control the size of molten pool by adjusting the input volume energy density. • Mo-rich precipitates are concentrated near the molten pool boundary. • The uneven cooling rate causes the concentrated distribution of precipitates. • The precipitate around molten pool boundary improves the dynamic mechanical property. [ABSTRACT FROM AUTHOR]

• Seven AlSi10Mg alloys with different construction angles were prepared and researched. • The grains in vertical planes change from columnar grains to irregularly arranged grains, and then to equiaxed grains. • The AlSi10Mg exhibites mechanical property anisotropy that is a result of grain structure, dispersed Si, and residual stress. In this study, seven AlSi10Mg bulks with different construction angles (0°, 15°, 30°, 45°, 60°, 75°, and 90°) were fabricated by selective laser melting (SLM). The effects of different construction angles on the microstructure and mechanical properties of AlSi10Mg alloys were investigated. Increasing the construction angle changed the laser track segments from an ellipse to a semi-ellipse and then to fish-scale, specifically again from a semi-ellipse to an ellipse, due to the decrease of the laser radiation area. Meanwhile, the grains in the vertical planes changed from columnar grains to irregularly arranged grains, and then to equiaxed grains. The 45° sample exhibited the highest hardness of 154.44 HV 0.1. The 60° sample had a good combination of strength and plasticity with a tensile strength of 463.54 MPa, yield strength of 283.37 MPa, and elongation of 9.25%. The observed mechanical property anisotropy of the current AlSi10Mg alloy was a result of the pores, equiaxed grain structure, ultra-fine equiaxed sub-grains, and working hardening. In addition, the difference in the sample microstructures was attributed to the construction angles and deposited layer area. [ABSTRACT FROM AUTHOR]