Understanding the effects of manufacturing attributes on damage
tolerance of additively manufactured parts and exploring synergy among
process-structure-properties. A Comprehensive review
Abstract
Additive Manufacturing(AM) has revolutionized the production industry by
offering design freedom with shorter lead times and reduced material
wastage. However, the damage tolerance of AM parts is a significant
concern due to their microstructural and geometric complexities, which
affect their mechanical performance. This article aims to provide a
comprehensive overview of the manufacturing parameters affecting the
damage tolerance of components produced by AM specifically selective
laser melting(SLM). Detailed discussions are presented on the effects of
manufacturing attributes on the microstructure, defects, and mechanical
characteristics of AM parts. Depending on these aspects, basic concepts
are studied and critically explained specifically for AM materials. The
basic criterion for damage-tolerant component design, the criterion for
fatigue and fracture properties, and the effect of the defects on
fatigue life are critically presented. In addition, the effect of
different types of gradation on the crack growth behavior of AM samples
processed by SLM is also investigated in depth. There is currently a
lack of a specific review study in the literature that establishes a
connection between process attributes and metallographic properties, and
their impact on the damage behavior of additively manufactured parts.
This gap in research highlights the need for a comprehensive review to
bridge this knowledge deficit and provide valuable insights for
understanding the relationships between manufacturing processes,
material characteristics, and the structural integrity of additively
manufactured components. This review concludes by addressing the
challenges and opportunities in designing and qualifying AM parts for
damage tolerance.