Additive manufacturing (AM) processes can produce three-dimensional (3D) near-net-shape parts based on computer-aided design (CAD) models. Compared to traditional manufacturing processes, AM processes can generate parts with intricate geometries, operational flexibility and reduced manufacturing time, thus saving time and money. On the other hand, AM processes face complex issues, including poor surface finish, unwanted microstructure phases, defects, wear tracks, reduced corrosion resistance and reduced fatigue life. These problems prevent AM parts from real-time operational applications. Post-processing techniques, including laser shock peening, laser polishing, conventional machining methods and thermal processes, are usually applied to resolve these issues. These processes have proved their capability to enhance the surface characteristics and physical and mechanical properties. In this study, various post-processing techniques and their implementations have been compiled. The effect of post-processing techniques on additively manufactured parts has been discussed. It was found that laser shock peening (LSP) can cause severe strain rate generation, especially in thinner components. LSP can control the surface regularities and local grain refinement, thus elevating the hardness value. Laser polishing (LP) can reduce surface roughness up to 95% and increase hardness, collectively, compared to the as-built parts. Conventional machining processes enhance surface quality; however, their influence on hardness has not been proved yet. Thermal post-processing techniques are applied to eliminate porosity up to 99.99%, increase corrosion resistance, and finally, the mechanical properties’ elevation. For future perspectives, to prescribe a particular post-processing technique for specific defects, standardization is necessary. This study provides a detailed overview of the post-processing techniques applied to enhance the mechanical and physical properties of AM-ed parts. A particular method can be chosen based on one’s requirements.

Powder flow and temperature distribution are recognized as essential factors in the laser melting deposition (LMD) process, which affect not only the layer formation but also its characteristics. In this study, two mathematical models were developed. Initially, the three-jet powder flow in the Gaussian shape was simulated for the LMD process. Next, the Gaussian powder flow was coaxially added along with the moving laser beam to investigate the effect of powder flow on temperature distribution at the substrate. The powder particles’ inflight and within melt-pool heating times were controlled to avoid vapors or plasma formation due to excessive heat. Computations were carried out via MATLAB software. A high-speed imaging camera was used to monitor the powder stream distribution, experimentally, while temperature distribution results were compared with finite element simulations and experimental analyses. A close correlation was observed among analytical computation, numerical simulations, and experimental results. An investigation was conducted to investigate the effect of the focal point position on powder stream distribution. It was found that the focal point position plays a key role in determining the shape of the powder stream, such that an increment in the distance from the focus point will gradually transform the powder stream from the Gaussian to Transition, and from the Transition to Annular streams. By raising the powder flow rate, the attenuation ratio prevails in the LMD process, hence, decreasing the laser energy density arriving at the substrate. The computations indicate that, if the particle’s heating temperature surpasses the boiling point, a strong possibility exists for vapors and plasma formation. Consequently, an excessive amount of laser energy is absorbed by the produced vapors and plasma, thus impeding the deposition process.

In this study, crack-free TiC/Ti composites with TiC content ranging from 0 to 15 wt.% were successfully fabricated using Direct Energy Deposition with a dual-feeder system that concomitantly delivered different amounts of both constituents into a high-power laser beam. The samples were investigated to evaluate the morphologies and distribution behavior of TiC. The microhardness values of the samples obtained under optimal processing conditions increased from 192 ± 5.3 HV_0.2 (pure Ti) to 300 ± 14.2 HV_0.2 (Ti + wt.% 15 TiC). Also, TiC has a significant impact on the Ti matrix, increasing the strength of TMCs up to 725 ± 5.4 MPa, while the elongation drastically decreased to 0.62 ± 0.04%. The wear rate is not proportionally affected by the rise content of TiC reinforcement; the hypoeutectic region of TMCs exhibited a wear rate of 2.45 mm³/N·m (Ti + wt.% 3 TiC) and a friction coefficient of 0.48 compared to the ones from the hypereutectic region, which measured a wear rate of 3.02 mm³/N·m (Ti + wt.% 15 TiC) and a friction coefficient of 0.63. The improved values of mechanical properties in the case of TMCs as compared to pure Ti are provided due to the solid solution strengthening of carbon and the fine grain strengthening. This work outlines a method for changing TiC morphologies to improve the hardness and tensile strength of TMCs fabricated starting from micro-scale powder.

Laser Melting Deposition (LMD) is a metal printing technique that allows for the manufacturing of large objects by Directed Energy Deposition. Due to its versatility in variation of parameters, the possibility to use two or more materials, to create alloys in situ or produce multi-layer structures, LMD is still being scientifically researched and is still far from industrial maturity. The structural testing of obtained samples can be time consuming and solutions that can decrease the samples analysis time are constantly proposed in the scientific literature. In this manuscript we present a quality improvement study for obtaining defect-free bulk samples of Ti6Al4V under X-Ray Computed Tomography (XCT) by varying the hatch spacing and distance between planes. Based on information provided by XCT, the experimental conditions were changed until complete elimination of porosity. Information on the defects in the bulk of the samples by XCT was used for feedback during parameters tuning in view of complete removal of pores. The research time was reduced to days instead of weeks or months of samples preparation and analysis by destructive metallographic techniques.

In this study a continuous wave Ytterbium-doped Yttrium Aluminum Garnet (Yb: YAG) disk laser has been used for welding of AlMg3 casted alloy. A high-speed imaging camera has been employed to record hot vapor plume features during the process. The purpose was to identify a mechanism of pores detection in real-time based on correlations between metallographic analyses and area/intensity of the hot vapor in various locations of the samples. The pores formation and especially the position of these pores had to be kept under control in order to weld thick samples. Based on the characterization of the hot vapor, it has been found that the increase of the vapor area that exceeded a threshold value (18.5 ± 1 mm²) was a sign of pores formation within the weld seam. For identification of the pores’ locations during welding, the monitored element was the hot vapor intensity. The hot vapor core spots having a grayscale level reaching 255 was associated with the formation of a local pore. These findings have been devised based on correlation between pores placement in welds cross-section microscopy images and the hot vapor plume features in those respective positions.

Additive manufacturing has recently become a key enabling technology in industrial fields, ranging from customized products for everyday usage to aerospace applications and small-batch industrial tooling. The future prospects extend up to the biofabrication of human organs. Ensuring the quality and repeatability of this process requires a systematic and comprehensive investigation of the underlying physical phenomena. In particular, melt-pool evolution is a critical feature, since irregularities in its spatial profile can influence microstructural evolution and weaken the integrity of the manufactured part. Microscale defects arising from balling and keyhole phenomena, often associated with recoil pressure, can severely degrade the quality of the resulting scanned track. This paper reviews the current state of optical approaches for melt-pool characterization and feature monitoring relevant to industrial laser additive manufacturing for process control and quality improvement, with a special focus on pyrometry and high-speed imaging. A single high-speed camera was generally used in experiments for melt-pool feature extraction, but two cameras were used to bypass emissivity values, which are otherwise difficult to obtain. Mathematical models were introduced to provide complementary information about melt-pool features, while artificial intelligence algorithms were used in other cases to process optical information. New melt-pool imaging databases and classifiers are expected in the near future to enable fast selection of appropriate process parameter windows, eliminating costly trial-and-error experiments.