Additive manufacturing of alloys with programmable microstructure and properties

Shubo Gao, Zhi Li, Steven Petegem, Junyu Ge, Sneha Goel, Joseph Vimal Vas, Vladimir Luzin, Zhiheng Hu, Hang Li Seet, Dario Ferreira Sanchez, Helena Swygenhoven, Huajian Gao and Matteo Seita ()
Additional contact information
Shubo Gao: Nanyang Technological University
Zhi Li: Agency for Science, Technology and Research (A*STAR)
Steven Petegem: Photon Science Division, Paul Scherrer Institute
Junyu Ge: Nanyang Technological University
Sneha Goel: Photon Science Division, Paul Scherrer Institute
Joseph Vimal Vas: Nanyang Technological University
Vladimir Luzin: Australian Nuclear Science & Technology Organisation (ANSTO)
Zhiheng Hu: Agency for Science, Technology and Research (A*STAR)
Hang Li Seet: Agency for Science, Technology and Research (A*STAR)
Dario Ferreira Sanchez: Photon Science Division, Paul Scherrer Institute
Helena Swygenhoven: Photon Science Division, Paul Scherrer Institute
Huajian Gao: Nanyang Technological University
Matteo Seita: University of Cambridge

Nature Communications, 2023, vol. 14, issue 1, 1-11

Abstract: Abstract In metallurgy, mechanical deformation is essential to engineer the microstructure of metals and to tailor their mechanical properties. However, this practice is inapplicable to near-net-shape metal parts produced by additive manufacturing (AM), since it would irremediably compromise their carefully designed geometries. In this work, we show how to circumvent this limitation by controlling the dislocation density and thermal stability of a steel alloy produced by laser powder bed fusion (LPBF) technology. We show that by manipulating the alloy’s solidification structure, we can ‘program’ recrystallization upon heat treatment without using mechanical deformation. When employed site-specifically, our strategy enables designing and creating complex microstructure architectures that combine recrystallized and non-recrystallized regions with different microstructural features and properties. We show how this heterogeneity may be conducive to materials with superior performance compared to those with monolithic microstructure. Our work inspires the design of high-performance metal parts with artificially engineered microstructures by AM.

Date: 2023
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DOI: 10.1038/s41467-023-42326-y

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