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Mohammad Porhonar, Yazdan Shajari, Seyed Hossein Razavi, Zahra-Sadat Seyedraoufi,
Volume 20, Issue 3 (September 2023)
Abstract

In this research, after pressing in a cylindrical mold, the AA 7075 alloy swarf was melted and cast in a wet sand mold. After rolling and cutting, sheets with two different thicknesses of 6 and 20 mm were obtained. The sheets after homogenization were solutionized at 485°C for 30 and 90 minutes, respectively, due to differences in thickness and thermal gradients. The solutionized samples were quenched in 3 polymer solutions containing 10, 30, and 50% Poly Alekylene Glycol. The results showed that melting, casting, rolling, and heat treatment of AA7075 alloy swarf similar properties to this alloy is achievable. Microstructural studies by optical microscopes (OM), Field Emission Scanning Electron Microscopy (FESEM), and X-ray diffraction (XRD) showed that by increasing the quenching rate after the solutionizing process, precipitation increases during aging. The tensile test results indicated that as the quench rate and internal energy increase, the diffusion driving force would increase the precipitation of alloying elements. Hence, this leads to an increase in hardness and reduction of its strain after aging.
Seyed Hossein Razavi, Amirhossein Riazi, Alireza Khavandi, Mostafa Amirjan, Mohsen Ostad Shabani, Hossein Davarzani, Yazdan Shajari,
Volume 22, Issue 2 (JUNE 2025)
Abstract

Additive manufacturing (AM) of metallic parts has gained significant attention in recent years due to its ability to produce components without traditional tooling such as molds, melting furnaces, or extensive raw material preparation. Its unique capability to fabricate complex geometries has revolutionized part design and enabled substantial weight reduction. This review first outlines the development trajectory of metal-based AM, with a particular focus on laser-based fusion methods, including Laser Powder Bed Fusion (LPBF) and Direct Laser Deposition (DLD). Understanding this evolution helps researchers identify both the capabilities and limitations of AM technologies, thereby enhancing their application in areas such as prototyping, mass production, and repair. Each metal possesses unique physical and chemical properties, which often make traditional manufacturing methods more challenging—especially for alloys with high strength, hardness, or temperature resistance. In this context, the review then focuses on nickel-based superalloys (NBSAs), which are widely used in high-temperature and high-stress environments but are particularly difficult to process using conventional techniques. Their application serves as a representative case study for evaluating the performance and feasibility of AM techniques for advanced materials. Furthermore, the future prospects of AM are discussed, including advancements in monitoring systems, integration of machine learning, and the development of AM-specific alloys. As a novel aspect, this work compares LPBF and DLD in terms of their advantages, limitations, and resulting material properties, along with a comparison to traditional manufacturing methods such as casting and wrought processing.
 

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