This article reviews published data on the mechanical properties of additively manufactured metallic materials. The additive manufacturing techniques utilized to generate samples covered in this review include powder bed fusion (e.g., EBM, SLM, DMLS) and directed energy deposition (e.g., LENS, EBF³). Although only a limited number of metallic alloy systems are currently available for additive manufacturing (e.g., Ti-6Al-4V, TiAl, stainless steel, Inconel 625/718, and Al-Si-10Mg), the bulk of the published mechanical properties information has been generated on Ti-6Al-4V. However, summary tables for published mechanical properties and/or key figures are included for each of the alloys listed above, grouped by the additive technique used to generate the data. Published values for mechanical properties obtained from hardness, tension/compression, fracture toughness, fatigue crack growth, and high cycle fatigue are included for as-built, heat-treated, and/or HIP conditions, when available. The effects of test orientation/build direction on properties, when available, are also provided, along with discussion of the potential source(s) (e.g., texture, microstructure changes, defects) of anisotropy in properties. Recommendations for additional work are also provided.

The intrinsic plasticity or brittleness of crystalline metals correlates with the ratio of the elastic shear modulus μ to the bulk modulus B; when the ratio μ/B exceeds a critical value, the metal is brittle. Sufficient data on elastic moduli and toughness are now available to permit an assessment for metallic glasses. We find a similar correlation, with the critical value of μ/B for metallic glasses (0.41–0.43) more sharply defined than for crystalline metals. This critical value applies also for annealing-induced embrittlement of metallic glasses. The clear correlation between mechanical behaviour (plasticity or brittleness) and μ/B assists in understanding flow and fracture mechanisms, and in guiding alloy design to alleviate brittleness of metallic glasses.

This overview highlights some of the key aspects regarding materials qualification needs across the additive manufacturing (AM) spectrum. AM technology has experienced considerable publicity and growth in the past few years with many successful insertions for non-mission-critical applications. However, to meet the full potential that AM has to offer, especially for flight-critical components (e.g., rotating parts, fracture-critical parts, etc.), qualification and certification efforts are necessary. While development of qualification standards will address some of these needs, this overview outlines some of the other key areas that will need to be considered in the qualification path, including various process-, microstructure-, and fracture-modeling activities in addition to integrating these with lifing activities targeting specific components. Ongoing work in the Advanced Manufacturing and Mechanical Reliability Center at Case Western Reserve University is focusing on fracture and fatigue testing to rapidly assess critical mechanical properties of some titanium alloys before and after post-processing, in addition to conducting nondestructive testing/evaluation using micro-computerized tomography at General Electric. Process mapping studies are being conducted at Carnegie Mellon University while large area microstructure characterization and informatics (EBSD and BSE) analyses are being conducted at Materials Resources LLC to enable future integration of these efforts via an Integrated Computational Materials Engineering approach to AM. Possible future pathways for materials qualification are provided.

We report a brittle Mg-based bulk metallic glass which approaches the ideal brittle behavior. However, a dimple structure is observed at the fracture surface by high resolution scanning electron microscopy, indicating some type of “ductile” fracture mechanism in this very brittle glass. We also show, from the available data, a clear correlation between the fracture toughness and plastic process zone size for various glasses. The results indicate that the fracture in brittle metallic glassy materials might also proceed through the local softening mechanism but at different length scales.