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As efforts associated with the exploration of multi-principal element alloys (MPEAs) using computational and data-intensive methods continue to rise, experimental realization and validation of the predicted material properties require high-throughput and combinatorial synthesis of these alloys. While additive manufacturing (AM) has emerged as the leading pathway to address these challenges and for rapid prototyping through part fabrication, extensive research on developing and understanding the process-structure-property correlations is imminent. In particular, directed energy deposition (DED) based AM of MPEAs holds great promise because of the boundless compositional variations possible for functionally graded component manufacturing as well as surface cladding. We analyze the recent efforts in DED of MPEAs, the microstructural evolution during the laser metal deposition of various transition and refractory elements, and assess the effects of various processing parameters on the material phase and properties. Our efforts suggest that the development of robust predictive approaches for process parameter selection and modifying the synthesis mechanisms are essential to enable DED platforms to repeatedly produce defect free, stable and designer MPEAs.
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Additive manufacturing of refractory metals and carbides for extreme environments: an overview
Refractory metals and their carbides possess extraordinary properties when subjected to high temperatures and extreme environments. Consequently, they can act as key material systems for advancing many sectors, including space, energy and defence. However, it has been difficult to process these materials using the conventional routes of manufacturing. Additive manufacturing (AM) has shown a lot of potential to overcome the challenges and develop new material systems with tailored properties. This review provides a fundamental understanding of the challenges in the processing of refractory metals and their carbides, including microcracking, formation of brittle oxide phases and high ductile to brittle transition temperature (DBTT). We also highlight some of the novel approaches that have been taken to improve the processability of these challenging material systems using AM. These include in-situ reactive printing, ultrasonic vibration, laser beam shaping, multi-laser deposition and substrate pre-heating with a focus on microstructural changes to improve the properties of printed parts.
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- Award ID(s):
- 2046523
- PAR ID:
- 10495102
- Publisher / Repository:
- SAGE Publications
- Date Published:
- Journal Name:
- Science and Technology of Welding and Joining
- Volume:
- 29
- Issue:
- 2
- ISSN:
- 1362-1718
- Format(s):
- Medium: X Size: p. 99-115
- Size(s):
- p. 99-115
- Sponsoring Org:
- National Science Foundation
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