Impact of metal additive manufacturing parameters on the powder bed fusion and direct energy deposition processes: a comprehensive review

Metal additive manufacturing (AM) has been recently acknowledged as a method to produce metal parts with complex geometries and unique characteristics. In general, metal AM components are used in applications where enhanced mechanical properties are required; thus it is essential to optimize the parameters that affect the metal AM processes. The immense advantages of metal AM technologies in the fields of production and manufacturing placed these technologies in the forefront of scientific sectors relevant to engineering, biomedical science and electronics. In recent years, many studies have been published analyzing the parameters which influence metal AM techniques to achieve advanced overall quality and optimized mechanical behavior of the fabricated products. Existing research has individually studied the influence of various factors on metal AM methods such as feedstock material properties, build orientation, printing conditions, infill patterns and post-processing procedures. The present study aims to review the research carried out until today identifying and classifying all parameters affecting metal AM, based on their impact on the quality of the final product. This survey intents to establish a process map of the categories which influence metal AM components. Additional recommendations, research gaps and directions towards the improvement of metal AM are also provided.

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