Current Status and Challenges of Powder Bed Fusion-Based Metal Additive Manufacturing: Literature Review

Powder bed fusion (PBF) is recognized as one of the most common additive manufacturing technologies because of its attractive capability of fabricating complex geometries using many possible materials. However, the quality and reliability of parts produced by this technology are observed to be crucial aspects. In addition, the challenges of PBF-produced parts are hot issues among stakeholders because parts are still insufficient to meet the strict requirements of high-tech industries. This paper discusses the present state of the art in PBF and technological challenges, with a focus on selective laser melting (SLM). The review work focuses mainly on articles that emphasize the status and challenges of PBF metal-based AM, and the study is primarily limited to open-access sources, with special attention given to the process parameters and flaws as a determining factor for printed part quality and reliability. Moreover, the common defects due to an unstrained process parameter of SLM and those needed to monitor and sustain the quality and reliability of components are encompassed. From this review work, it has been observed that there are several factors, such as laser parameters, powder characteristics, material properties of powder and the printing chamber environments, that affect the SLM printing process and the mechanical properties of printed parts. It is also concluded that the SLM process is not only expensive and slow compared with conventional manufacturing processes, but it also suffers from key drawbacks, such as its reliability and quality in terms of dimensional accuracy, mechanical strength and surface roughness.

Automated summary

Powder bed fusion (PBF) is a common additive manufacturing technology for fabricating complex geometries using various materials, however the quality and reliability of parts produced by this technology are crucial aspects. This study focuses on selective laser melting (SLM) and discusses the present state of the art and technological challenges in PBF. The review work highlights the status and challenges of PBF metal-based AM, with a focus on process parameters and flaws that affect part quality and reliability.