Additive manufacturing of Fe-Mn-Si-based shape memory alloys: state of the art, challenges and opportunities

Additive manufacturing (AM) constitutes the new paradigm in materials processing and its use on metals and alloys opens new unforeseen possibilities, but is facing several challenges regarding the design of the microstructure, which is particularly awkward in the case of functional materials, like shape memory alloys (SMA), as they require a robust microstructure to withstand the constraints appearing during their shape change. In the present work, the attention is focused on the AM of the important Fe-Mn-Si-based SMA family, which is attracting a great technological interest in many industrial sectors. Initially, an overview on the design concepts of this SMA family is offered, with special emphasis to the problems arising during AM. Then, such concepts are considered in order to experimentally develop the AM production of the Fe-20Mn-6Si-9Cr-5Ni (wt%) SMA through laser powder bed fusion (LPBF). The complete methodology is approached, from the gas atomization of powders to the LPBF production and the final thermal treatments to functionalize the SMA. The microstructure is characterized by scanning and transmission electron microscopy after each step of the processing route. The reversibility of the epsilon martensitic transformation and its evolution on cycling are studied by internal friction and electron microscopy. An outstanding 14% of fully reversible thermal transformation of epsilon martensite is obtained. The present results show that, in spite of the still remaining challenges, AM by LPBF offers a good approach to produce this family of Fe-Mn-Si-based SMA, opening new opportunities for its applications

Internal friction associated with ? martensite in shape memory steels produced by casting route and through additive manufacturing: Influence of thermal cycling on the martensitic transformation.

Among the different families of shape memory alloys (SMA), the Fe-Mn-Si-Cr-Ni alloys have attracted a renewed interest because of its low cost, high corrosion resistance and high recovery strength during the shape memory effect, and the new technologies of additive manufacturing offer unforeseen possibilities for this family of SMA. In the present work, the reversible gamma - epsilon martensitic transformation (MT), responsible for the shape memory effect, is studied in two Fe-Mn-Si-Cr-Ni alloys with high (20.2 wt%) and low (15.8 wt%) Mn content, produced by the conventional route of casting and rolling, in comparison with the MT in another similar alloy, with intermediate Mn content (19.4 wt%), which was produced by gas atomization and additive manufacturing through laser metal deposition. The forward and reverse gamma - epsilon MT is studied by mechanical spectroscopy through the internal friction spectra and the dynamic modulus variation, together with a parallel microstructural characterization including in-situ observation of the gamma - epsilon MT during cooling and heating at the scanning electron microscope. The evolution of the transformed fraction of epsilon martensite, evaluated through the integral area of the internal friction peak, was followed along thermal cycling in all three alloys. Both, the internal friction and the electron microscopy studies show that the epsilon martensite amount increases very fast during the first few cycles, and then decreases with a tendency towards its stabilization for many tens of cycles. The results show that the gamma - epsilon MT is more stable on cycling in the additive manufactured sample than in the conventionally processed samples, opening new avenues for designing shape memory steels to be specifically processed through additive manufacturing