The Use of Selective Laser Melting as a Method of New Materials Development

Selective laser melting (SLM) is a fast growing, Additive Manufacturing (AM) technology, that creates opportunities for manufacturing complex geometries (both monolithic volumes and spatial structures) directly from metal powders and CAD 3D computer model. Therefore, the SLM technology is recognized as a manufacturing technology of the future. Many industry leaders are implementing selective laser melting into their production standards, e.g.: automotive, aviation, space and medicine companies. SLM technology can also be used for the development of new materials, through the possibility of manufacturing elements from various mixtures of metal powders. The methodology presented in this article allows to expand the use of SLM in a wide range of industries and test the properties of new materials on functional parts and 3D specimens. This methodology has been illustrated by an example of Inconel 718-Rhenium alloy. The following path of new materials development will be described: Development of material requirements → Powder material characteristics and powder preparation → Development of laser melting processing parameters → Microscopic observations and mechanical testing → Post-process development (HT, HIP, CNC) → Production of a demonstrator parts.