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Over the last decade, the enormous potential of metal additive manufacturing (AM) processes has led these technologies to establish their position in many industries. Much effort is being made toward their widespread application; however, much remains to be done to achieve full industrialization of these processes. Therefore, many companies, research centers and universities are investing in comprehensive research and development activities in order to further promote the industrialization of metal AM. This review traces the progress of metal AM technologies through an investigation of patents. In the present study, beam-based metal AM patents were searched through the Orbit Intelligence database. First, the number of patents per year was studied, indicating that, as expected, there is strong growth in AM patenting activities. The patents were afterward examined in order to highlight the key players in the field, and it was found that the main players investing in this market are: multidisciplinary companies, AM machine producers, end users working, especially in the aerospace sector, universities and research centers. The patents were then analyzed to understand the technology domains covered by each key player and their trend of investments. Finally, the patents in the field of Materials and Metallurgy were studied individually to identify the main topics faced by the most used alloy classes: Al-, Ni- and Ti-based alloys and steels. The extensive study of these patents clearly indicated that the main gaps to fill in metal AM are strongly material dependent and that it is possible to find correlations between the alloy classes, their main industrial applications and their specific AM processability issues. The current study provides insights into global trends that can help industrial markets to identify the right investment direction and research to identify topics for future investigation.

Conformal cooling coils have been developed during the last decades through the use of additive manufacturing (AM) technologies. The main goal of this study was to analyze how the presence of an internal channel that could act as a conformal cooling coil could affect compressive strength and quasi-elastic gradient of AlSi10Mg lattice structures produced by laser powder bed fusion (LPBF). Three different configurations of samples were tested in compression at 25 °C and 200 °C. The reference structures were body centered cubic (BBC) in the core of the samples with vertical struts alongZ(BCCZ) lattices in the outer perimeter, labelled as NC samples. The main novelty consisted in inserting a straight elliptical channel and a 45° elliptical channel inside the BCCZ lattice structures, labelled as SC and 45C samples respectively. All the samples were then tested in as-built (AB) condition, and after two post process heat treatments, commonly used for AlSi10Mg LPBF industrial components, a stress relieving (SR) and a T6 treatment. NC lattice structures AB exhibited an overall fragile fracture and therefore the SC and 45C configuration samples were tested only after thermal treatments. The test at 25 °C showed that all types of samples were characterized by negligible variations in their quasi-elastic gradients and yield strength. On the contrary, the general trend of stress-strain curves was influenced by the presence of the channel and its position. The test at 200 °C showed that NC, SC and 45C samples after SR and T6 treatments exhibited a metal-foam like deformation.

Directed energy deposition (DED) process is recognized as an alternative technology to produce the complex-shape AISI 316L components. The critical production step in this technology is the optimization of process parameters that can directly affect the final properties of the components. To optimize the process parameters, the residual defects of specimens produced with different combinations of process parameters are evaluated, and the optimum condition is chosen. Therefore, the residual defects assessment is a vital step in finding the optimum process parameters; therefore, this evaluation should be carried out carefully. One of the main issues in the production of AISI 316L by DED process is oxidation during the process that should be considered besides the other defects such as porosity and cracks. However, the identification between the oxides and porosities is not an easy task, and so this study aims to provide more clear insight into the evaluation of pores and oxides in DED 316L samples. The outcomes of this work show that at the best process parameters suitable for a porosity-free sample, there are some oxides that can be misinterpreted as porosity and consequently deteriorate the mechanical properties of the dense sample.

Among recently developed high-strength and lightweight alloys, the high-performance Scalmalloy® certainly stands out for laser powder bed fusion (LPBF) production. The primary goal of this study was to optimize the Scalmalloy® LPBF process parameters by setting power values suitable for the use of lab-scale machines. Despite that these LPBF machines are commonly characterized by considerably lower maximum power values (around 100 W) compared to industrial-scale machines (up to 480 W), they are widely used when quick setup and short processing time are needed and a limited amount of powder is available. In order to obtain the optimal process parameters, the influence of volumetric energy density (VED) on the sample porosity, microstructure and mechanical properties was accurately studied. The obtained results reveal the stability of the microstructural and mechanical behaviour of the alloy for VEDs higher than 175 Jmm−3. In this way, an energy-and-time-saving choice at low VEDs can be taken for the LPBF production of Scalmalloy®. After identifying the low-power optimized process parameters, the effects of the heat treatment on the microstructural and mechanical properties were investigated. The results prove that low-VED heat-treated samples produced with an LPBF lab-scale machine can achieve outstanding mechanical performance compared with the results of energy-intensive industrial production.

Directed Energy Deposition (DED) is an additive manufacturing process that enables the production of large metal components by melting the feedstock material while being deposited. An improvement of the production speed of this process would further increase its applicability in many industrial fields. The DED building rate is strictly related to the building parameters adopted, in particular to the laser spot diameter, which also affects the build accuracy and the surface quality of the components. The possibility of using a variable laser spot would result in a significant increase in the production rate in bulky zones, while also providing a good surface quality where needed. In the present work, an oscillating scanning strategy was used to create a large apparent laser spot (+ 170% of the nominal value) to produce 316L stainless steel samples via DED. The optimisation of the DED parameters with the oscillating strategy was performed using the single scan tracks (SSTs) approach. The morphologies of the SSTs obtained with different process parameters were assessed and the geometrical features related to the melt pools were analysed in order to select the most suitable X and Z displacements for the production of the cubic samples. The analyses of the cubes revealed that, if the correct overlap among nearby scans is selected, it is possible to obtain dense samples with all the oscillating diameters tested. Finally, comparing the building rate and powder efficiency values confirmed that this method can accelerate the building process and improve its overall performance. Graphical Abstract

This work focuses on the effect of different heat treatments on the Ti-6Al-4V alloy processed by means of electron beam melting (EBM). Super β-transus annealing was conducted at 1050 °C for 1 h on Ti-6Al-4V samples, considering two different cooling paths (furnace cooling and water quenching). This heat treatment induces microstructural recrystallization, thus reducing the anisotropy generated by the EBM process (columnar prior-β grains). Subsequently, the annealed furnace-cooled and water-quenched samples were aged at 540 °C for 4 h. The results showed the influence of the aging treatment on the microstructure and the mechanical properties of the annealed EBM-produced Ti-6Al-4V. A comparison with the traditional processed heat-treated material was also conducted. In the furnace-cooled specimens consisting of lamellar α+β, the aging treatment improved ductility and strength by inducing microstructural thickening of the α laths and reducing the β fraction. The effect of the aging treatment was also more marked in the water-quenched samples, characterized by high tensile strengths but limited ductility due to the presence of martensite. In fact, the aging treatment was effective in the recovery of the ductility loss, maintaining high tensile strength properties due to the variation in the relative number of α/α’ interfaces resulting from α’ decomposition. This study, therefore, offers an in-depth investigation of the potential beneficial effects of the aging treatment on the microstructure and mechanical properties of the EBM-processed super β-transus heat-treated Ti-6Al-4V alloy under different cooling conditions.

Laser powder bed fusion (LPBF) is an additive manufacturing technology that implies using metal powder as a raw material. The powders suitable for this kind of technology must respect some specific characteristics. Controlled gas atomization and post-processing operations can strongly affect the final properties of the powders, and, as a consequence, the characteristics of the bulk components. In fact, a complete characterization of the powders is mandatory to fully determine their properties. Beyond the most used tests, such as the volume particle size distribution (PSD) and flowability, the PSD number, the Hausner ratio and the oxidation level can give additional information otherwise not detectable. The present work concerns the complete characterization of two AlSi10Mg powders: a commercial-grade gas atomized powder and a laboratory-scale gas atomized counterpart. The laboratory-scale gas atomization allows to better manage the amount of the fine particles and the oxidation level. As a consequence, a higher particle packing can be reached with an increase in the final density and tensile strength of the LPBF bulk samples.

In this research work, nanocomposite coatings of nickel reinforced with graphene oxide (GOs) were produced by electrodeposition on steel substrate discs from the modified Watts bath. The resultant coatings were evaluated in terms of their surface morphology by atomic force microscopy and thermomechanical and electrochemical corrosion characteristics. The electrodeposited coatings showed variation in the electrochemical and thermomechanical behavior as the function of GO content where they show the optimum characteristics for 0.1 wt.% GO. The relatively lower concentrations of GO produced composites with greater surface homogeneity and lower roughness, whereas when the GO content is increased, the coatings show increased surface roughness. Electrochemical corrosion resistance of nickel is increased by incorporation of GO up to 0.1 wt.% due to decreased grain boundary area in the coatings and the uniform dispersion of the nanophase ensured by prior probe sonication and magnetic stirring during the co-deposition. The nickel composite coatings with 0.1 wt.% GO also showed improved thermomechanical behavior with higher recovery at 473 K.

Urgent environmental challenges and emerging additive manufacturing (AM) technologies push research towards more performant and new materials. In the field of metallurgy, high entropy alloys (HEAs) have recently represented a topic of intense research because of their promising properties, such as high temperature strength and stability. Moreover, this class of multi-principal element alloys (MPEAs) have opened up researcher community to unexplored compositional spaces, making prosper literature of high-throughput methodologies and tools for rapidly screening large number of alloys. However, none of the methods has been aimed to design new MPEAs for AM process known as selective laser melting (SLM) so far. Here we conducted nanoindentation testing on single scan tracks of elemental powder blends and pre-alloyed powders after ball milling of AlTiCuNb and AlTiVNb. Results show that nanoindentation can represent an effective technique to gain information about phase evolution during laser scanning, contributing to accelerate the development of new MPEAs.

Directed energy deposition is an additive manufacturing technology which usually relies on prototype machines or hybrid systems, assembled with parts from different producers. Because of this lack of standardization, the optimization of the process parameters is often a mandatory step in order to develop an efficient building process. Although, this preliminary phase is usually expensive both in terms of time and cost. The single scan approach allows to drastically reduce deposition time and material usage, as in fact only a stripe per parameters combination is deposited. These specimens can then be investigated, for example in terms of geometrical features (e.g. growth, width) and microstructure to assess the most suitable process window. In this work, Ti-6Al-4V single scans, produced by means of directed energy deposition, corresponding to a total of 50 different parameters combinations, were analyzed, focusing on several geometrical features and relative parameters correlations. Moreover, considering the susceptibility of the material to oxygen pick-up, the necessity of an additional shielding gas system was also evaluated, by comparing the specimens obtained with and without using a supplementary argon flow. A process window, which varies according to the user needs, was found together with a relationship between microstructure and process parameters, in both shielding scenarios.Graphic Abstract

Laser Powder Bed Fusion (LPBF) is an additive manufacturing technology which has been the subject of thorough research and successfully adopted in several industrial sectors. Among all the processable classes of materials, titanium alloys are especially interesting due to their favourable combination of mechanical properties and corrosion resistance. Most of the literature focuses on Ti-6Al-4V, although there are other alloys which are widely applied in fields that can benefit from the advantages of LPBF techniques, such as Ti-6Al-2Sn-4Zr-6Mo, thus far not investigated for this technology. This alloy is generally preferred to Ti-6Al-4V for the production of some components in the aerospace industry, mostly due to its superior strength. In this work, the most suitable process window for this alloy was investigated. Samples produced with two different combinations of process parameters, located in the selected process window, were then thoroughly studied in order to assess the effect of building conditions on the microstructure, phases and mechanical properties of the as-built and heat-treated material. To do so, an X-ray diffraction analysis was conducted with the aim of determining the phase composition and lattice parameters. Moreover, microstructural features, such as α” needles and α lath widths, were analysed in order to correlate the thermal history of the process to the final microstructure of the specimens. Furthermore, the hardness and the tensile properties of the alloy processed by LPBF were quantified and compared with the data available in the literature relative to conventional manufacturing technologies.

Ti-48Al-2Cr-2Nb (Ti-48-2-2) is an intermetallic alloy belonging to a family of gamma-TiAl intermetallic alloys that are attracting significant attention. Electron Beam Melting (EBM) process is today the only manufacturing process that allows effective production of parts made by these kinds of alloys. Proper process control avoids high temperatures in the surrounding areas that may generate significant residual stresses that could cause micro-cracks. In this paper, an investigation on the residual stress state on Ti-48-2-2 parts is carried out using the hole drilling method. In particular, the influence of EBM process parameters is evaluated in order to understand the effects of the residual stresses on part integrity.

This work aims to investigate the effect of the process parameters on the densification and microstructure of Inconel 939 (IN939) alloy processed by laser powder bed fusion (LPBF). IN939 is a Ni-based superalloy with high creep and corrosion resistance that can be used up to around 850 &deg, C under load, resulting in higher operative temperatures than the ones commonly allowed for Inconel 718 and Inconel 625 alloys (around 650 &deg, C). However, this alloy can suffer from poor weldability involving possible crack formation. In order to minimize the residual porosity and the cracking density, specific process parameters were investigated. The parameters to generate IN939 samples almost pores-free (porosity &le, 0.22%) with a cracking density &le, 1.36 mm/mm2 as well as samples almost crack-free (&le, 0.10 mm/mm2) with limited residual porosity (&le, 0.89%) were determined. The microstructure revealed fine dendritic/cellular structures with the formation of sub-micrometric phases. A high concentration of these phases was also found along the intergranular cracks, suggesting that their presence, coupled to the high thermal stresses, can be the primary reason for crack formation during the LPBF process.

Blown powder additive manufacturing technologies are not restricted to the use of a process chamber. This feature allows to build larger components with respect to conventional powder bed processes. This peculiarity is mostly promising for manufacturing large components or repairing/rebuilding parts of large systems. The main downside of using an open environment, even if a protective shielding gas system is adopted, is the lack of control of process atmosphere. This is particularly critical for titanium alloys which are very sensitive to oxygen/nitrogen pick-up, they have a detrimental effect on ductility, by causing embrittlement and possibly leading to the formation of cracks. It is then important to address how environmental factors, such as process atmosphere and platform temperature, impact not only on the processability but also on the final component properties, both from a compositional and mechanical point of view. The correlations between these environmental factors and microstructure, interstitials content, grain size, and hardness were investigated. Moreover, the Hall&ndash, Petch equation was then adopted to additive manufacturing microstructures, characterized by a columnar grain morphology, and used to further investigate the relationship intercurring between grains and hardness and how different microstructures might influence this correlation.

Additive manufacturing (AM) processes allow producing the complex components in a layerwise fashion. The complexity includes the design of lighter and stronger components by using lattice structures that can be quickly realized through AM technologies. However, the mechanical behaviour of lattice structures is not completely known, especially in the post-treated state. Thus, this work aims to explore the effect of post-treatment on the compressive strength of specimens with lattice structures. The samples are produced using Ti-6Al-4V powder processed by Electron Beam Melting (EBM). The outcomes of this work confirm the correlation between the heat treatment and final mechanical properties.

Despite the extensive capabilities of Laser-Powder Directed Energy Deposition (LP-DED), compared to other metal additive manufacturing processes, the use of LP-DED in industry is still limited as a result of the limited knowledge on the relationships between the process parameters and mechanical behaviour. In this work, the quality of AISI 316L samples, produced by means of LP-DED and evaluated in terms of surface roughness, residual stresses and microstructure, is linked to the scanning strategy. The outcomes confirm that the deposition strategy plays a key role in the definition of the final properties of specimens.

Electron beam melting (EBM) process is an additive manufacturing process largely used to produce complex metallic components made of high-performance materials for aerospace and medical applications. Especially, lattice structures made by Ti–6Al–4V have represented a hot topic for the industrial sectors because of having a great potential to combine lower weights and higher performances that can also be tailored by subsequent heat treatments. However, the little knowledge about the mechanical behaviour of the lattice structures is limiting their applications. The present work aims to provide a comprehensive review of the studies on the mechanical behaviour of the lattice structures made of Ti–6Al–4V. The main steps to produce an EBM part were considered as guidelines to review the literature on the lattice performance: (1) design, (2) process and (3) post-heat treatment. Thereafter, the correlation between the geometrical features of the lattice structure and their mechanical behaviour is discussed. In addition, the correlation among the mechanical performance of the lattice structures and the process precision, surface roughness and working temperature are also reviewed. An investigation on the studies about the properties of heat-treated lattice structure is also conducted.

In Selective Laser Melting (SLM) layers of atomized powder are spread sequentially on a building platform and melted locally by a laser beam. The melt pool is quenched by the underlying material. SLM of AlSi10Mg alloys results in the development of microstructures consisting of supersaturated primary Al-rich phase surrounded by varied amounts of Al-Si eutectic. The origin of such microstructure is not fully understood. For insight into this issue, this work compares the results of processing AlS10Mgi alloys by SLM and by single-step rapid solidification techniques: Melt Spinning (MS) and Copper Mould Casting (CMC) achieving a range of cooling rates and microstructures which are analysed by means of microscopy, XRD and DSC. The results obtained in these experiments together with the literature available on rapidly solidified Al-Si alloys suggest a correlation among microstructures of the products made with the three techniques. Data on lattice parameter and enthalpy of Si precipitation from primary Al concur in indicating that Si supersaturation scales in the order SLM > CMC > MS. The type and size of microstructural features, i.e. cells, columns, fibrous and lamellar eutectic, reveal the role of solidification conditions (undercooling, recalescence) and precipitation in the solid state for all techniques. Dendrite growth modelling validates the solidification results.

Copper/graphene nanoplatelet (GNP) nanocomposites were produced by a wet mixing method followed by a classical powder metallurgy technique. A qualitative evaluation of the structure of graphene after mixing indicated that wet mixing is an appropriate dispersion method. Thereafter, the effects of two post-processing techniques such as repressing–annealing and hot isostatic pressing (HIP) on density, interfacial bonding, hardness, and thermal and electrical conductivity of the nanocomposites were analyzed. Density evaluations showed that the relative density of specimens increased after the post-processing steps so that after HIPing almost full densification was achieved. The Vickers hardness of specimens increased considerably after the post-processing techniques. The thermal conductivity of pure copper was very low in the case of the as-sintered samples containing 2 to 3 pct porosity and increased considerably to a maximum value in the case of HIPed samples which contained only 0.1 to 0.2 pct porosity. Electrical conductivity measurements showed that by increasing the graphene content electrical conductivity decreased.

Classical powder metallurgy followed by either hot isostatic pressing (HIPing) or repressing–annealing process was used to produce Cu–graphene nanoplatelets (GNPs) nanocomposites in this work. A wet mixing method was used to disperse the graphene within the matrix. The results show that a uniform dispersion of GNPs at low graphene contents could be achieved, whereas agglomeration of graphene was revealed at higher graphene contents. Density evaluations showed that the relative density of pure copper and copper composites increased by using the post-processing techniques. However, it should be noticed that the efficiency of HIPing was remarkably higher than repressing–annealing process, and through the HIPing, fully dense samples were achieved. The Vickers hardness results showed that the reconsolidation steps can improve the mechanical strength of the specimens up to 50% owing to the progressive porosity elimination after reconsolidation. The thermal conductivity results of pure copper and composites at high temperatures showed that the post-processing techniques could enhance the conductivity of materials significantly.

Aluminum and copper matrix nanocomposites reinforced by graphene nanoplatelets (GNPs) were successfully fabricated by a wet mixing method followed by conventional powder metallurgy. The uniform dispersion of GNPs within the metal matrices showed that the wet mixing method has a great potential to be used as a mixing technique. However, by increasing the GNPs content, GNPs agglomeration was more visible. DSC and XRD of Al/GNPs nanocomposites showed that no new phase formed below the melting point of Al. Microstructural observations in both nanocomposites reveal the evident grain refinement effect as a consequence of GNPs addition. The interfacial bonding evaluation shows a poor interfacial bonding between GNPs and Al, while the interfacial bonding between Cu and GNPs is strong enough to improve the properties of the Cu/GNPs nanocomposites. In both composites, the coefficient of thermal expansion decreases as a function of GNPs while, their hardness is improved by increasing the GNPs content as well as their elastic modulus.

This paper provides an overview on the main additive manufacturing/3D printing technologies suitable for many satellite applications and, in particular, radio-frequency components. In fact, nowadays they have become capable of producing complex net-shaped or nearly net-shaped parts in materials that can be directly used as functional parts, including polymers, metals, ceramics, and composites. These technologies represent the solution for low-volume, high-value, and highly complex parts and products.

Two-dimensional graphene plateletes with unique mechanical, electrical and thermo-physical properties could attract more attention for their employed as reinforcements in the production of new metal matrix nanocomposites (MMNCs), due to superior characteristics, such as being lightweight, high strength and high performance. Over the last years, due to the rapid advances of nanotechnology, increasing demand for the development of advanced MMNCs for various applications, such as structural engineering and functional device applications, has been generated. The purpose of this work is to review recent research into the development in the powder-based production, property characterization and application of magnesium, aluminum, copper, nickel, titanium and iron matrix nanocomposites reinforced with graphene. These include a comparison between the properties of graphene and another well-known carbonaceous reinforcement (carbon nanotube), following by powder-based processing strategies of MMNCs above, their mechanical and tribological properties and their electrical and thermal conductivities. The effects of graphene distribution in the metal matrices and the types of interfacial bonding are also discussed. Fundamentals and the structure–property relationship of such novel nanocomposites have also been discussed and reported.

The aim of this work is to compare the corrosion resistance of nickel-base Alloy 625 (UNS N06625) produced by laser powder bed fusion with that obtained via conventional casting and hot working. Cyclic potentiodynamic polarization and potentiostatic tests were performed in order to evaluate the corrosion resistance of the differently manufactured alloys according to ASTM G5, and in NaCl 0.6 M solution at pH 7 and pH 3, at 40°C. The electrochemical characterization was carried out on the as-produced alloy and after annealing at 980°C for 32 minutes (according to ASTM B446). This heat treatment was also performed on the commercial hot worked alloy. Two surface conditions, namely as-built and polished surfaces, were investigated on the additive manufactured specimens. The alloy produced by laser powder bed fusion was not susceptible to pitting in the considered environments and had a good localized corrosion resistance, slightly higher than that of traditional wrought material. However, as predicted, the corrosion resistance of the as-built surfaces increased after mechanical polishing. The correlation between the corrosion performance and microstructure is also discussed.

Aluminum alloys are key materials in additive manufacturing (AM) technologies thanks to their low density that, coupled with the possibility to create complex geometries of these innovative processes, can be exploited for several applications in aerospace and automotive fields. The AM process of these alloys had to face many challenges because, due to their low laser absorption, high thermal conductivity and reduced powder flowability, they are characterized by poor processability. Nowadays mainly Al-Si alloys are processed, however, in recent years many efforts have been carried out in developing new compositions specifically designed for laser based powder bed AM processes. This paper reviews the state of the art of the aluminum alloys used in the laser powder bed fusion process, together with the microstructural and mechanical characterizations.