Nitinol (nickel-titanium or Ni-Ti) is the most utilized shape memory alloy due to its good superelasticity, shape memory effect, low stiffness, damping, biocompatibility, and corrosion resistance. Various material characteristics, such as sensitivity to composition and production thermal gradients, make conventional methods ineffective for the manufacture of high quality complex Nitinol components. These issues can be resolved by modern additive manufacturing (AM) methods which can produce net or near-net shape parts with highly precise and complex Nitinol structures. Compared to Laser Engineered Net Shape (LENS), Selective Laser Melting (SLM) has the benefit of more easily creating a high quality local inert atmosphere which protects chemically-reactive Nitinol powders to a higher degree. In this paper, the most recent publications related to the SLM processing of Nitinol are reviewed to identify the various influential factors involved and process-related issues. It is reported how powder quality and material composition have a significant effect on the produced microstructures and phase transformations. The effect of heat treatments after SLM fabrication on the functional and mechanical properties are noted. Optimization of several operating parameters were found to be critical in fabricating Nitinol parts of high density. The importance of processing parameters and related thermal cooling gradient which are crucial for obtaining the correct phase structure for shape memory capabilities are also presented. The paper concludes by presenting the significant findings and areas of prospective future research in relation to the SLM processing of Nitinol.

Laser-Powder Bed Fusion (L-PBF) of metallic parts is a highly multivariate process. An understanding of powder feedstock properties is critical to ensure part quality. In this paper, a detailed examination of two commercial stainless steel 316L powders produced using the gas atomization process is presented. In particular, the effects of the powder properties (particle size and shape) on the powder rheology were examined. The results presented suggest that the powder properties strongly influence the powder rheology and are important factors in the selection of suitable powder for use in an additive manufacturing (AM) process. Both of the powders exhibited a strong correlation between the particle size and shape parameters and the powder rheology. Optical microscope images of melt pools of parts printed using the powders in an L-PBF machine are presented, which demonstrated further the significance of the powder morphology parameters on resulting part microstructures.

In this work, pure aluminium powders of different average particle size were compacted, sintered into discs and tested for mechanical strength at different strain rates. The effects of average particle size (15, 19, and 35 μm), sintering rate (5 and 20 °C/min) and sample indentation test speed (0.5, 0.7, and 1.0 mm/min) were examined. A compaction pressure of 332 MPa with a holding time of six minutes was used to produce the green compacted discs. The consolidated green specimens were sintered with a holding time of 4 h, a temperature of 600 °C in an argon atmosphere. The resulting sintered samples contained higher than 85% density. The mechanical properties and microstructure were characterized using indentation strength measurement tests and SEM analysis respectively. After sintering, the aluminium grain structure was observed to be of uniform size within the fractured samples. The indentation test measurements showed that for the same sintering rate, the 35 μm powder particle size provided the highest radial and tangential strength while the 15 μm powder provided the lowest strengths. Another important finding from this work was the increase in sintered sample strength which was achieved using the lower sinter heating rate, 5 °C/min. This resulted in a tangential stress value of 365 MPa which was significantly higher than achieved, 244 MPa, using the faster sintering heating rate, 20 °C/min.