Additive manufacturing of steel–bronze bimetal by shaped metal deposition: interface characteristics and tensile properties

Tungsten inert gas arc welding–based shaped metal deposition is a novel additive manufacturing technology which can be used for fabricating solid dense parts by melting a cold wire on a substrate in a layer-by-layer manner via continuous DC arc heat. The shaped metal deposition method would be an alternative way to traditional manufacturing methods, especially for complex featured and large-scale solid parts manufacturing, and it is particularly used for aerospace structural components, manufacturing, and repairing of die/molds and middle-sized dense parts. This article presents the designing, constructing, and controlling of an additive manufacturing system using tungsten inert gas plus wire–based shaped metal deposition method. The aim of this work is to design and develop tungsten inert gas plus wire–based shaped metal deposition system to be used for fabricating different components directly from computer-aided design data with minimum time consumed in programming and less boring task compared to conventional robotic systems. So, this article covers the important design steps from computer-aided design data to the final deposited part. The developed additive system is capable of producing near-net-shaped components of sizes not exceeding 400 mm in three-dimensional directly from computer-aided design drawing. The results showed that the developed system succeeded to produce near-net-shaped parts for various features of SS308LSi components. Additionally, workshop tests have been conducted in order to verify the capability and reliability of the developed additive manufacturing system. The developed system is also capable of reducing the buy-to-fly ratio from 5 to 2 by reducing waste material from 1717 to 268 g for the sample components.

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Additive manufacturing of W–Fe composites using laser metal deposition: Microstructure, phase transformation, and mechanical properties

Materials Science and Engineering A ◽

10.1016/j.msea.2021.141036 ◽

2021 ◽

Vol 811 ◽

pp. 141036

Author(s):

Hui Chen ◽

Lei Ye ◽

Yong Han ◽

Chao Chen ◽

Jinglian Fan

Keyword(s):

Mechanical Properties ◽

Phase Transformation ◽

Additive Manufacturing ◽

Metal Deposition ◽

Laser Metal Deposition

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Finite element modeling of multi-pass welding and shaped metal deposition processes

Computer Methods in Applied Mechanics and Engineering ◽

10.1016/j.cma.2010.02.018 ◽

2010 ◽

Vol 199 (37-40) ◽

pp. 2343-2359 ◽

Cited By ~ 100

Author(s):

Michele Chiumenti ◽

Miguel Cervera ◽

Alessandro Salmi ◽

Carlos Agelet de Saracibar ◽

Narges Dialami ◽

...

Keyword(s):

Finite Element ◽

Finite Element Modeling ◽

Metal Deposition ◽

Element Modeling ◽

Shaped Metal Deposition ◽

Deposition Processes

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Plasma Metal Deposition for Metallic Materials

10.5772/intechopen.101448 ◽

2021 ◽

Author(s):

Enrique Ariza Galván ◽

Isabel Montealegre Meléndez ◽

Cristina Arévalo Mora ◽

Eva María Pérez Soriano ◽

Erich Neubauer ◽

...

Keyword(s):

Additive Manufacturing ◽

Metal Deposition ◽

Welding Parameters ◽

Matrix Composites ◽

Large Size ◽

Wide Range ◽

Direct Energy ◽

Lightweight Alloys ◽

Near Net Shape ◽

Feedstock Material

Plasma metal deposition (PMD®) is a promising and economical direct energy deposition technique for metal additive manufacturing based on plasma as an energy source. This process allows the use of powder, wire, or both combined as feedstock material to create near-net-shape large size components (i.e., >1 m) with high-deposition rates (i.e., 10 kg/h). Among the already PMD® processed materials stand out high-temperature resistance nickel-based alloys, diverse steels and stainless steels commonly used in the industry, titanium alloys for the aerospace field, and lightweight alloys. Furthermore, the use of powder as feedstock also allows to produce metal matrix composites reinforced with a wide range of materials. This chapter presents the characteristics of the PMD® technology, the welding parameters affecting additive manufacturing, examples of different fabricated materials, as well as the challenges and developments of the rising PMD® technology.

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Build-up strategies for additive manufacturing of three dimensional Ti-6Al-4V-parts produced by laser metal deposition

Journal of Laser Applications ◽

10.2351/1.4997852 ◽

2018 ◽

Vol 30 (2) ◽

pp. 022001 ◽

Cited By ~ 9

Author(s):

Felix Spranger ◽

Benjamin Graf ◽

Michael Schuch ◽

Kai Hilgenberg ◽

Michael Rethmeier

Keyword(s):

Additive Manufacturing ◽

Three Dimensional ◽

Metal Deposition ◽

Laser Metal Deposition

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Additive Manufacturing for Crack Repair Applications in Metals

Additive Manufacturing Technologies From an Optimization Perspective - Advances in Logistics, Operations, and Management Science ◽

10.4018/978-1-5225-9167-2.ch004 ◽

2019 ◽

pp. 77-101

Author(s):

Tawanda Marazani ◽

Daniel Makundwaneyi Madyira ◽

Esther Titilayo Akinlabi

Keyword(s):

Additive Manufacturing ◽

Crack Detection ◽

Metal Deposition ◽

Maintenance And Repair ◽

Freeform Fabrication ◽

3D Cad ◽

Repair Technique ◽

Ti Alloys ◽

Crack Repair ◽

Am Applications

Additive manufacturing (AM) builds intricate parts from 3D CAD model data in successive layers. AM offers several advantages and has become a preferred freeform fabrication, processing, manufacturing, maintenance, and repair technique for metals, thermoplastics, ceramics, and composites. When using laser, it bears several names, which include laser additive manufacturing, laser additive technology, laser metal deposition, laser engineered net shape, direct metal deposition, and laser solid forming. These technologies use a laser beam to locally melt the powder or wire and the substrate that fuse upon solidification. AM is mainly applied in the aerospace and biomedical industries. Titanium (Ti) alloys offer very attractive properties much needed in these industries. This chapter explores AM applications for crack repairs in Ti alloys. Metal cracking industrial challenges, crack detection and repair methods, challenges, and milestones for AM repair of cracks in Ti alloys are also discussed.

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