Laser Metallic Additive Manufacturing Technologies by Thermal-Mechanical Interaction

This book introduces the laser hybrid additive manufacturing technology (LHAM) with alternately thermal and mechanical effects for the high-performance manufacturing of key components. Metal additive manufacturing (AM) technologies have made considerable progress in the basic theoretical field since its invention in the 1970s. However, there are still some difficulties in the coordinated control of the structure and performance, containing the challenges of “structure control” against deformation and cracking of the formed metallic components incurred by internal stress and “performance control” against poor fatigue property of formed metallic components incurred by metallurgical defects. This book surveys the most relevant papers about the influence of laser shock wave on the microstructural evolution, residual stress, metallurgical defect, and mechanical properties that have become the foundation to elucidate the principles and effects of LHAM technology. This book is separated into four parts to fully present the LHAM technology. The first part reviews the background of LHAM technology. The second part explains the theoretical basis of the thermal effects of laser additive manufacturing (LAM) and mechanical effects of laser shock peening (LSP). The other two parts specifically describe the microstructural evolution, residual stress, metallurgical defect, and mechanical properties using LHAM technology. This book benefits the audience in the field of mechanical engineering and materials sciences, since LHAM technology is suitable for the manufacturing and applications of the key components of aero-engine. The analysis in the book helps the audience deeply understand the mechanism of LHAM technology. The authors’ unique thinking about LHAM technology also runs through the book, which may enlighten the audience to further develop LHAM technology.

General Introduction.- Theoretical basis of laser metallic additive manufacturing technologies by thermal-mechanical interaction.- Effect of laser shock peening on microstructure and mechanical properties of laser powder bed fusion Ti6Al4V alloy.- Significant improvement in the strength-toughness and isotropy of laser powder bed fusion Ti6Al4V alloy by combining heat treatment with subsequent laser shock peening.- Effects of laser shock peening on the hot corrosion behaviour of laser powder bed fusion Ti6Al4V titanium alloy.- The role of annealing heat treatment in high-temperature oxidation resistance of laser powder bed fused Ti6Al4V alloy subjected to massive laser shock peening treatment.- Effect of interlayer laser shock peening on microstructure and mechanical properties of laser powder bed fusion Ti6Al4V alloy.- Distributions of residual stress and metallurgical defects of Ti6Al4V alloy via laser additive manufacturing by thermal-mechanical interaction.- Microstructural evolution and tensile property enhancement of remanufactured Ti6Al4V using hybrid manufacturing of laser directed energy deposition with laser shock peening.

Jinzhong Lu is an internationally well-known professor in laser shock peening (LSP) and laser additive manufacturing (LAM). He first proposed LSP-induced surface nano-crystallization of metallic materials, built a relationship between the LSP-induced strain rate and the local microstructure, and developed microstructural evolutions of FCC, HCP, and BCC materials. He has published 20 invention patents and more than 150 papers relating to LSP and LAM in international journals, including International Journal of Machine Tools and Manufacturing, Acta Materialia, International Journal of Plasticity, Corrosion Science, etc., which have received over 3600 citations. His contributions in fundamental research and experimental data provide useful information for researchers and engineers in LSP and LAM.

Haifei Lu received his Ph.D. in Mechanical Engineering from Jiangsu University under the supervision of Prof. Jinzhong Lu. He has focused on laser additive manufacturing (LAM) and laser shock peening (LSP) to design materials with optimal microstructures and mechanical properties for ten years. He has published 12 papers relating to LAM and LSP in international journals, including International Journal of Machine Tools and Manufacturing, Additive Manufacturing, Corrosion Science, Journal of Materials Processing Technology, etc. Additionally, one paper is the most cited research paper of International Journal of Machine Tools and Manufacturing in 2020–2021, which focused on the 3D-LSP-induced microstructural evolution of Ti-6Al-4V alloy.

Kaiyu Luo is currently working as a professor at the School of Mechanical Engineering at Jiangsu University of China. She has focused on the LSP process, analysis of the interface and surface of materials, and investigation of microstructural evolution and corrosion resistances. She had published 20 invention patents and more than 150 papers in peer-reviewed international journals, including International Journal of Machine Tools and Manufacturing, Acta Materialia, International Journal of Plasticity, Corrosion Science, Materials & Design, International Journal of Fatigue, Applied Surface Science, etc., which have received over 3000 citations with an H-index of 29 according to the Scopus database.