A Review of Metal Fabricated with Laser- and Powder-Bed Based Additive Manufacturing Techniques: Process, Nomenclature, Materials, Achievable Properties, and its Utilization in the Medical Sector

Purpose For any 3D model with chambers to be fabricated in powder-bed additive manufacturing processes such as SLM and SLS, powders are trapped in the chambers of the finished model. This paper aims to design a shortest network with the least number of outlets for efficiently leaking the trapped powders. Design/methodology/approach This paper proposes a nonlinear objective with linear constraints for solving the channel design problem and a particle swarm optimization algorithm to solve the nonlinear system. Findings Structural optimization for the channel network leads to fairly short channels in the interior of the 3D models and very few outlets on the model surface, which achieves the cleaning of the powders while causing almost the least changes to the model. Originality/value This paper reveals the NP-harness of computing the shortest channel network with the least number of outlets. The proposed approach helps the design of lightweight models using the powder-bed additive manufacturing techniques.

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Hybrid additive manufacturing of steels and alloys

Manufacturing Review ◽

10.1051/mfreview/2020005 ◽

2020 ◽

Vol 7 ◽

pp. 6

Author(s):

Vladimir V. Popov ◽

Alexander Fleisher

Keyword(s):

Additive Manufacturing ◽

Energy Deposition ◽

Modern Trend ◽

Production Chain ◽

Direct Energy Deposition ◽

Powder Bed ◽

Direct Energy ◽

Manufacturing Techniques ◽

Traditional Manufacturing

Hybrid additive manufacturing is a relatively modern trend in the integration of different additive manufacturing techniques in the traditional manufacturing production chain. Here the AM-technique is used for producing a part on another substrate part, that is manufactured by traditional manufacturing like casting or milling. Such beneficial combination of additive and traditional manufacturing helps to overcome well-known issues, like limited maximum build size, low production rate, insufficient accuracy, and surface roughness. The current paper is devoted to the classification of different approaches in the hybrid additive manufacturing of steel components. Additional discussion is related to the benefits of Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) approaches for hybrid additive manufacturing of steel components.

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Study of Arc-wire and Laser-wire processes for the realization of Ti-6Al-4V alloy parts

MATEC Web of Conferences ◽

10.1051/matecconf/202032103002 ◽

2020 ◽

Vol 321 ◽

pp. 03002

Author(s):

A. Ayed ◽

G. Bras ◽

H. Bernard ◽

P. Michaud ◽

Y. Balcaen ◽

...

Keyword(s):

Additive Manufacturing ◽

Travel Speed ◽

Feed Speed ◽

Laser Additive Manufacturing ◽

Powder Bed ◽

Wire Feed Speed ◽

Manufacturing Techniques ◽

Parameter Ranges ◽

Wire Arc Additive Manufacturing ◽

Wire Feed

Arc-wire or laser-wire additive manufacturing seems promising because it allows large parts to be produced with significant deposition rates (ten times higher than powder bed additive manufacturing), for a lower investment cost. These additive manufacturing techniques are also very interesting for the construction or the repair of parts. A versatile 3D printing device using a Wire Arc Additive Manufacturing (WAAM) station or laser device Wire Laser Additive Manufacturing (WLAM) for melting a filler wire is developed to repair and build large titanium parts. The final objectives of the study are to optimize the process parameters to control the dimensional stability, the metallurgical and mechanical properties of the produced parts. In this paper, an experimental study is carried out to determine the first order process parameter ranges (synergic law, laser power, wire feed speed, travel speed) appropriate for these two techniques, for repair or construction parts on Ti-6 Al-4V.

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Correlation between the Energy Input and the Microstructure of Additively Manufactured Cobalt-Chromium

Defect and Diffusion Forum ◽

10.4028/www.scientific.net/ddf.379.157 ◽

2017 ◽

Vol 379 ◽

pp. 157-165 ◽

Cited By ~ 5

Author(s):

Leonhard Hitzler ◽

Philipp Williams ◽

Markus Merkel ◽

Wayne Hall ◽

Andreas Öchsner

Keyword(s):

Fibre Laser ◽

Cobalt Chromium ◽

Recent Trial ◽

Cocrmo Alloy ◽

Powder Bed ◽

Fine Grained ◽

Medical Sector ◽

Manufacturing Techniques ◽

Fabrication Parameters ◽

Made In

Powder-bed based additive manufacturing techniques are of high interest for the medical sector and recent trial studies have shown their feasibility. Due to the rapid improvements made in the machinery and the related changes in the type and characteristics of the utilized power source, optimizations regarding the fabrication parameters tend to differ amongst various machines. In this study, a parameter optimization was undertaken for a biocompatible dental CoCrMo alloy on a SLM 280HL machine, featuring a 400 W fibre laser. It was shown that the availability of higher laser powers enables a more energy efficient fabrication. Moreover, parameter sets for fast and economic fabrication, as well as for high density and fine-grained microstructure, were defined.

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Powder Bed Fusion Additive Manufacturing Using Critical Raw Materials: A Review

Materials ◽

10.3390/ma14040909 ◽

2021 ◽

Vol 14 (4) ◽

pp. 909

Author(s):

Vladimir V. Popov ◽

Maria Luisa Grilli ◽

Andrey Koptyug ◽

Lucyna Jaworska ◽

Alexander Katz-Demyanetz ◽

...

Keyword(s):

Additive Manufacturing ◽

3D Printing ◽

Industrial Revolution ◽

Raw Materials ◽

Powder Bed ◽

Energy Applications ◽

Supply And Distribution ◽

Manufacturing Techniques ◽

Key Enabling Technologies ◽

Critical Raw Materials

The term “critical raw materials” (CRMs) refers to various metals and nonmetals that are crucial to Europe’s economic progress. Modern technologies enabling effective use and recyclability of CRMs are in critical demand for the EU industries. The use of CRMs, especially in the fields of biomedicine, aerospace, electric vehicles, and energy applications, is almost irreplaceable. Additive manufacturing (also referred to as 3D printing) is one of the key enabling technologies in the field of manufacturing which underpins the Fourth Industrial Revolution. 3D printing not only suppresses waste but also provides an efficient buy-to-fly ratio and possesses the potential to entirely change supply and distribution chains, significantly reducing costs and revolutionizing all logistics. This review provides comprehensive new insights into CRM-containing materials processed by modern additive manufacturing techniques and outlines the potential for increasing the efficiency of CRMs utilization and reducing the dependence on CRMs through wider industrial incorporation of AM and specifics of powder bed AM methods making them prime candidates for such developments.

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Laser Welding of AISI 316L Stainless Steel Produced by Additive Manufacturing or by Conventional Processes

Journal of Manufacturing and Materials Processing ◽

10.3390/jmmp5040136 ◽

2021 ◽

Vol 5 (4) ◽

pp. 136

Author(s):

Morgane Mokhtari ◽

Pierrick Pommier ◽

Yannick Balcaen ◽

Joel Alexis

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

Laser Welding ◽

Aisi 316L Stainless Steel ◽

Powder Bed ◽

Size Limitation ◽

Common Technique ◽

Cold Rolled ◽

Manufacturing Techniques ◽

Complex Parts

Among all the additive manufacturing techniques, Laser Powder Bed Fusion (LBPF), also called Selective Laser Melting (SLM), is the most common technique due to its high capability of building complex parts with generally improved mechanical properties. One of the main drawbacks of this technique is the sample size limitation, which depends on elaborating chamber dimensions. In this study, we investigate the viability of obtaining large parts with the laser welding of additive manufactured plates. A comparison of the microstructure and the tensile mechanical properties of SLM-welded plates and cold-rolled welded plates was performed. This paper shows the possibility of obtaining defect-free parts. Even if welding has a low impact on the microstructure of the SLM samples, fractures are located on the fusion zone, and a decrease in ductility of around 30% compared to the base metal is observed.

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Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM)

Materials ◽

10.3390/ma12071121 ◽

2019 ◽

Vol 12 (7) ◽

pp. 1121 ◽

Cited By ~ 54

Author(s):

Tiago A. Rodrigues ◽

V. Duarte ◽

R.M. Miranda ◽

Telmo G. Santos ◽

J.P. Oliveira

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

Three Dimensional ◽

Current Status ◽

Powder Bed ◽

Significant Research ◽

Manufacturing Techniques ◽

Materials Used ◽

Metallic Parts ◽

General Perspective

Additive manufacturing has revolutionized the manufacturing paradigm in recent years due to the possibility of creating complex shaped three-dimensional parts which can be difficult or impossible to obtain by conventional manufacturing processes. Among the different additive manufacturing techniques, wire and arc additive manufacturing (WAAM) is suitable to produce large metallic parts owing to the high deposition rates achieved, which are significantly larger than powder-bed techniques, for example. The interest in WAAM is steadily increasing, and consequently, significant research efforts are underway. This review paper aims to provide an overview of the most significant achievements in WAAM, highlighting process developments and variants to control the microstructure, mechanical properties, and defect generation in the as-built parts; the most relevant engineering materials used; the main deposition strategies adopted to minimize residual stresses and the effect of post-processing heat treatments to improve the mechanical properties of the parts. An important aspect that still hinders this technology is certification and nondestructive testing of the parts, and this is discussed. Finally, a general perspective of future advancements is presented.

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Design & Manufacture of a High Performance Bicycle Crank by Additive Manufacturing

10.20944/preprints201807.0306.v1 ◽

2018 ◽

Author(s):

Iain McEwen ◽

David E Cooper ◽

Jay Warnett ◽

Nadia Kourra ◽

Mark Williams ◽

...

Keyword(s):

Additive Manufacturing ◽

High Performance ◽

Complex Geometry ◽

Topology Optimisation ◽

Element Analysis ◽

Powder Bed ◽

Static Testing ◽

Material Usage ◽

Build Time ◽

Manufacturing Techniques

Additive Manufacturing (AM) provides an opportunity to fundamentally redesign components previously limited by conventional manufacturing techniques. A new process for this workflow of design, manufacture by Powder Bed Fusion (PBF) and validation is presented, to which a case study of a crank for a high performance racing bicycle is applied. Topology optimisation generated conceptually ideal geometry from which a functional design was interpreted. Design for AM considerations were employed to reduce build time, material usage and post-processing labour. PBF was employed to manufacture the parts, and the build quality assessed using Computed Tomography (CT). Static and dynamic functional testing was performed and compared to a Finite Element Analysis (FEA). CT confirmed good build quality of tall, complex geometry with no significant geometrical deviation from CAD over 0.5 mm. Static testing proved performance close to current market leaders, although failure under fatigue occurred after just 2495 ± 125 cycles, the failure mechanism was consistent in both its form and location. These physical results were representative of those simulated, thus validating the FEA. This research demonstrates a complete workflow from design, manufacture, post-treatment and validation of a highly loaded PBF manufactured component, offering practitioners with a validated approach to the application of PBF. 

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