Intentional oxidation and laser remelting of highly‐reflective pure Cu for its high‐quality additive manufacturing

AbstractIn the last years, Additive Manufacturing, thanks to its capability of continuous improvements in performance and cost-efficiency, was able to partly replace and redefine well-established manufacturing processes. This research is based on the idea to achieve great cost and operational benefits especially in the field of tool making for injection molding by combining traditional and additive manufacturing in one process chain. Special attention is given to the surface quality in terms of surface roughness and its optimization directly in the Selective Laser Melting process. This article presents the possibility for a remelting process of the SLM parts as a way to optimize the surfaces of the produced parts. The influence of laser remelting on the surface roughness of the parts is analyzed while varying machine parameters like laser power and scan settings. Laser remelting with optimized parameter settings considerably improves the surface quality of SLM parts and is a great starting point for further post-processing techniques, which require a low initial value of surface roughness.

Download Full-text

Towards Wire and Arc Additive Manufacturing of High-Quality Parts

Procedia CIRP ◽

10.1016/j.procir.2020.01.180 ◽

2020 ◽

Vol 95 ◽

pp. 54-59

Author(s):

Daniel Baier ◽

Andreas Bachmann ◽

Michael F. Zaeh

Keyword(s):

Additive Manufacturing ◽

High Quality

Download Full-text

A Review on Additive Manufacturing of Micromixing Devices

Micromachines ◽

10.3390/mi13010073 ◽

2021 ◽

Vol 13 (1) ◽

pp. 73

Author(s):

Marina Garcia-Cardosa ◽

Francisco-Javier Granados-Ortiz ◽

Joaquín Ortega-Casanova

Keyword(s):

Life Cycle ◽

Additive Manufacturing ◽

High Performance ◽

Future Prospects ◽

High Quality ◽

Printing Technology ◽

Wide Range ◽

The Moment ◽

Manufacturing Technologies

In recent years, additive manufacturing has gained importance in a wide range of research applications such as medicine, biotechnology, engineering, etc. It has become one of the most innovative and high-performance manufacturing technologies of the moment. This review aims to show and discuss the characteristics of different existing additive manufacturing technologies for the construction of micromixers, which are devices used to mix two or more fluids at microscale. The present manuscript discusses all the choices to be made throughout the printing life cycle of a micromixer in order to achieve a high-quality microdevice. Resolution, precision, materials, and price, amongst other relevant characteristics, are discussed and reviewed in detail for each printing technology. Key information, suggestions, and future prospects are provided for manufacturing of micromixing machines based on the results from this review.

Download Full-text

Uncertainty Quantification in Metallic Additive Manufacturing Through Data-Driven Modelling Based on Multi-Scale Multi-Physics Models and Limited Experiment Data

Volume 1: Additive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering; Manufacturing Equipment and Automation ◽

10.1115/msec2020-8379 ◽

2020 ◽

Author(s):

Zhuo Wang ◽

Chen Jiang ◽

Mark F. Horstemeyer ◽

Zhen Hu ◽

Lei Chen

Keyword(s):

Temperature Field ◽

Additive Manufacturing ◽

Uncertainty Quantification ◽

Surrogate Modeling ◽

Data Driven ◽

Modeling Framework ◽

High Quality ◽

Experimental Calibration ◽

Multi Scale ◽

Metallic Additive

Abstract One of significant challenges in the metallic additive manufacturing (AM) is the presence of many sources of uncertainty that leads to variability in microstructure and properties of AM parts. Consequently, it is extremely challenging to repeat the manufacturing of a high-quality product in mass production. A trial-and-error approach usually needs to be employed to attain a product with high quality. To achieve a comprehensive uncertainty quantification (UQ) study of AM processes, we present a physics-informed data-driven modeling framework, in which multi-level data-driven surrogate models are constructed based on extensive computational data obtained by multi-scale multi-physical AM models. It starts with computationally inexpensive metamodels, followed by experimental calibration of as-built metamodels and then efficient UQ analysis of AM process. For illustration purpose, this study specifically uses the thermal level of AM process as an example, by choosing the temperature field and melt pool as quantity of interest. We have clearly showed the surrogate modeling in the presence of high-dimensional response (e.g. temperature field) during AM process, and illustrated the parameter calibration and model correction of an as-built surrogate model for reliable uncertainty quantification. The experimental calibration especially takes advantage of the high-quality AM benchmark data from National Institute of Standards and Technology (NIST). This study demonstrates the potential of the proposed data-driven UQ framework for efficiently investigating uncertainty propagation from process parameters to material microstructures, and then to macro-level mechanical properties through a combination of advanced AM multi-physics simulations, data-driven surrogate modeling and experimental calibration.

Download Full-text

Invited review article: Strategies and processes for high quality wire arc additive manufacturing

Additive Manufacturing ◽

10.1016/j.addma.2018.06.020 ◽

2018 ◽

Vol 22 ◽

pp. 672-686 ◽

Cited By ~ 70

Author(s):

C.R. Cunningham ◽

J.M. Flynn ◽

A. Shokrani ◽

V. Dhokia ◽

S.T. Newman

Keyword(s):

Additive Manufacturing ◽

Review Article ◽

High Quality ◽

Wire Arc Additive Manufacturing

Download Full-text

Towards Selective Volumetric Additive Manufacturing and Processing of Ceramics

Volume 1: 39th Computers and Information in Engineering Conference ◽

10.1115/detc2019-98195 ◽

2019 ◽

Author(s):

A. P. Iliopoulos ◽

J. G. Michopoulos ◽

J. C. Steuben ◽

A. J. Birnbaum ◽

B. D. Graber ◽

...

Keyword(s):

Additive Manufacturing ◽

Ceramic Powder ◽

Ceramic Materials ◽

High Quality ◽

Analysis And Design ◽

Spatially Resolved ◽

Selective Approach ◽

Scientists And Engineers ◽

Processing Techniques ◽

Am Processes

Abstract The development of advanced additive manufacturing (AM) and material processing techniques is currently a topic of great interest to broad communities of scientists and engineers. In particular, there is a need for AM processes capable of producing functional and high-quality components at a faster rate than is currently achievable. In response to this demand, the present work introduces the initial steps of a novel spatially-resolved and selective approach for processing volumetric regions of ceramic materials. The proposed method utilizes microwave radiation to heat material at desired locations within a domain filled with ceramic powder. Using this principle of operation, a number of methods for implementation of this process are proposed. As a first step, a multiphysics computational methodology and an associated model that allows for the analysis and design of relevant processing systems is introduced. Additionally, a number of simulations demonstrating the feasibility of the proposed methodology are presented. Based on these preliminary results, we conclude with a discussion of ongoing and future efforts to fully realize this technology.

Download Full-text

Possible Applications of Additive Manufacturing Technologies in Shipbuilding: A Review

Machines ◽

10.3390/machines8040084 ◽

2020 ◽

Vol 8 (4) ◽

pp. 84

Author(s):

Marcin Ziółkowski ◽

Tomasz Dyl

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

3D Printing ◽

Weight Reduction ◽

Maritime Industry ◽

High Quality ◽

Printing Technology ◽

3D Printing Technology ◽

Manufacturing Technologies ◽

Very High

3D printing conquers new branches of production due to becoming a more reliable and professional method of manufacturing. The benefits of additive manufacturing such as part optimization, weight reduction, and ease of prototyping were factors accelerating the popularity of 3D printing. Additive manufacturing has found its niches, inter alia, in automotive, aerospace and dentistry. Although further research in those branches is still required, in some specific applications, additive manufacturing (AM) can be beneficial. It has been proven that additively manufactured parts have the potential to out perform the conventionally manufactured parts due to their mechanical properties; however, they must be designed for specific 3D printing technology, taking into account its limitations. The maritime industry has a long-standing tradition and is based on old, reliable techniques; therefore it implements new solutions very carefully. Besides, shipbuilding has to face very high classification requirements that force the use of technologies that guarantee repeatability and high quality. This paper provides information about current R&D works in the field of implementing AM in shipbuilding, possible benefits, opportunities and threats of implementation.

Download Full-text