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<p>Titanium alloys are vital for lightweight aviation equipment due to their high strength-to-weight and stiffness ratios. Selective laser melting (SLM) enables the fabrication of intricate titanium-alloy components, optimizing design and manufacturing flexibility. However, the layered nature of SLM induces significant residual stresses, leading to deformation and reduced dimensional accuracy. Support structures are crucial for stabilizing building conditions, dissipating heat, and mitigating thermal and residual stress issues. This review explores the challenges of residual stress and deformation control in SLM, specifically for aviation titanium alloys. It evaluates the impact of SLM support structures on part formation and considers optimizing the SLM process for these materials. Current research suggests that controlling temperature and thermal fields during the build process primarily involves adjusting key parameters, which may not fully address residual stresses from suboptimal conditions. Future research should focus on optimizing support structures and their distributions, regulating heat transfer during forming, and controlling deformation with consideration of support structures. Initial studies should investigate how support structures affect heat transfer and temperature fields during SLM. Additionally, the relationship between SLM process parameters and support structures concerning residual stress in complex titanium-alloy components requires further exploration. Finally, efforts should concentrate on controlling deformation in complex SLM titanium-alloy components and improving forming quality through process and support structure optimization. And a set of normalized quantitative metrics, including residual stress reduction rate and distortion control efficiency was introduced to achieve qualitative descriptions of residual stress and deformation. This approach will advance the conceptual and technological understanding of SLM, contributing to better lightweight design and manufacturing of aviation equipment.</p>

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Deformation control in selective laser melting of complex aviation titanium alloy components: advances, challenges, and future prospects

  • 期刊论文

  • 发表日期：

    2025年11月18日

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  • Mengdi Gao,
  • Qingyang Wang,
  • Lei Li,
  • Qiang Li,
  • Conghu Liu,
  • Zhifeng Liu

摘要

Titanium alloys are vital for lightweight aviation equipment due to their high strength-to-weight and stiffness ratios. Selective laser melting (SLM) enables the fabrication of intricate titanium-alloy components, optimizing design and manufacturing flexibility. However, the layered nature of SLM induces significant residual stresses, leading to deformation and reduced dimensional accuracy. Support structures are crucial for stabilizing building conditions, dissipating heat, and mitigating thermal and residual stress issues. This review explores the challenges of residual stress and deformation control in SLM, specifically for aviation titanium alloys. It evaluates the impact of SLM support structures on part formation and considers optimizing the SLM process for these materials. Current research suggests that controlling temperature and thermal fields during the build process primarily involves adjusting key parameters, which may not fully address residual stresses from suboptimal conditions. Future research should focus on optimizing support structures and their distributions, regulating heat transfer during forming, and controlling deformation with consideration of support structures. Initial studies should investigate how support structures affect heat transfer and temperature fields during SLM. Additionally, the relationship between SLM process parameters and support structures concerning residual stress in complex titanium-alloy components requires further exploration. Finally, efforts should concentrate on controlling deformation in complex SLM titanium-alloy components and improving forming quality through process and support structure optimization. And a set of normalized quantitative metrics, including residual stress reduction rate and distortion control efficiency was introduced to achieve qualitative descriptions of residual stress and deformation. This approach will advance the conceptual and technological understanding of SLM, contributing to better lightweight design and manufacturing of aviation equipment.