Effects of porosity on the mechanical properties of additively manufactured components: a critical review

Abstract

In the present review, the effect of porosity on the mechanical properties of the fabricated parts, which are additively manufactured by powder bed fusion and filament extrusion-based technologies, are discussed in detail. Usually, additive manufacturing (AM) processes based on these techniques produce the components with a significant amount of pores. The porosity in these parts typically takes two forms: pores with irregular shapes (called keyholes) and uniform (spherical) pores. These pores are present at different locations, such as surface, sub-surface, interior bulk material, between the deposited layers and at filler/matrix interface, which critically affect the corrosion resistance, fatigue strength, stiffness, mechanical strength, and fracture toughness properties, respectively. Therefore, it is essential to study and understand the influence of pores on the mechanical properties of AM fabricated parts. The technologies of AM can be employed in the manufacturing of components with the desired porous structure through the topology optimization process of scaffolds and lattices to improve their toughness under a specific load. The undesirable effect of pores can be eliminated by using defects-free raw materials, optimizing the processing parameters, and implementing suitable post-processing treatment. The current review grants a more comprehensive understanding of the effect of porous defects on mechanical performance and provides a mechanistic basis for reliable applications of additively manufactured components.