Influence of the manufacturing parameters of an AlMg5 wire–based hybrid production process on quality and mechanical properties

AbstractHybrid manufacturing processes are known for combining the advantages of additive manufacturing and more traditional manufacturing processes such as machining to create components of complex geometry while minimising material waste. The trend towards lightweight design, especially in view of e-mobility, gives aluminium materials an important role to play. This study examines the use of aluminium alloys in laser metal wire deposition (LMWD) processes with subsequent subtractive machining, which is considerably more difficult due to the different process-related influences. The investigations are focussed on the influence of the differently controlled laser power on the shape accuracy, the microstructure, and the hardness of the AlMg5 test components after the LMWD process with subsequent subtractive machining by turning. The long-term goal of the investigations is to increase the stability of the hybrid production process of AlMg5 components with defined dimensional accuracy and mechanical properties.

Download Full-text

Variance Quantification of Different Additive Manufacturing Processes for Acoustic Meta Materials

INTER-NOISE and NOISE-CON Congress and Conference Proceedings ◽

10.3397/in-2021-2211 ◽

2021 ◽

Vol 263 (4) ◽

pp. 2708-2723

Author(s):

Manuel Bopp ◽

Arn Joerger ◽

Matthias Behrendt ◽

Albert Albers

Keyword(s):

Mechanical Properties ◽

Additive Manufacturing ◽

Production Process ◽

Laser Scanning ◽

Mode Shapes ◽

Manufacturing Processes ◽

3D Laser Scanning ◽

Fused Filament Fabrication ◽

Manufacturing Techniques ◽

Different Levels

Many concepts for acoustic meta materials rely on additive manufacturing techniques. Depending on the production process and material of choice, different levels of precision and repeatability can be achieved. In addition, different materials have different mechanical properties, many of which are frequency dependent and cannot easily be measured directly. In this contribution the authors have designed different resonator elements, which have been manufactured utilizing Fused Filament Fabrication with ABSplus and PLA, as well as PolyJet Fabrication with VeroWhitePlus. All structures are computed in FEA to obtain the calculated Eigenfrequencies and mode shapes, with the respective literature values for each material. Furthermore, the dynamic behavior of multiple instances of each structure is measured utilizing a 3D-Laser-Scanning Vibrometer under shaker excitation, to obtain the actual Eigenfrequencies and mode shapes. The results are then analyzed in regards to variance between different print instances, and in regards to accordance between measured and calculated results. Based on previous work and this analysis the parameters of the FEA models are updated to improve the result quality.

Download Full-text

vELECTROPLATING POLYMER BASED ADDITIVE MANUFACTURED PARTS FOR ENHANCED STRUCTURAL PERFORMANCE

10.12783/asc36/35881 ◽

2021 ◽

Author(s):

WARUNA SENEVIRATNE, ◽

JOHN TOMBLIN ◽

BRANDON SAATHOFF

Keyword(s):

Additive Manufacturing ◽

Fused Deposition Modeling ◽

Thickness Variation ◽

Manufacturing Processes ◽

Fused Deposition ◽

Aerospace Applications ◽

Electroplated Coating ◽

Traditional Manufacturing ◽

Plastic Parts ◽

Subtractive Machining

Additive manufacturing has been adopted in many aerospace and defense applications to reduce weight and buy-to-fly ratios of low-volume high- complexity parts. Polymer-based additive manufacturing processes such as Fused Deposition Modeling (FDM) has enabled aerospace manufactures to improve the structural efficiency of parts through generative design or topology optimization. This level of design freedom did not exist in the past due to limitations associated with traditional manufacturing processes such as subtractive machining. Improvements in the material and the maturation of the FDM process has led to the production of many non-structural flightworthy parts used in aircraft today. Polymer-based additive manufacturing can be further leveraged in aerospace applications with the addition of electroplated coatings that act as reinforcement. While many of the commonly known electroplated coating applications involve enhancing the part appearance, electroplated coatings can also improve the strength, stiffness, and durability of plastic parts. Depending on the use case, the thickness of the metallic plating material (combination of copper and nickel) can be tailored to achieve the desired composite properties (metal and polymer). In this research, the tensile and flexural mechanical properties were assessed for Ultem™ 9085 FDM printed specimens and compared to specimens with metallic coating thicknesses of approximately 75-μm, 150-μm, and 300-μm. Non- destructive inspections using x-ray computed tomography were performed prior to mechanical testing to assess the electroplated coating thickness variation and overall quality.

Download Full-text

Impact of vapor polishing on surface quality and mechanical properties of extruded ABS

Rapid Prototyping Journal ◽

10.1108/rpj-03-2017-0039 ◽

2018 ◽

Vol 24 (2) ◽

pp. 501-508 ◽

Cited By ~ 8

Author(s):

Clayton Neff ◽

Matthew Trapuzzano ◽

Nathan B. Crane

Keyword(s):

Mechanical Properties ◽

Surface Roughness ◽

Surface Quality ◽

Complex Geometry ◽

Substantial Impact ◽

Solvent Vapor ◽

Content Type ◽

Minimal Impact ◽

End Use ◽

Traditional Manufacturing

Purpose Additive manufacturing (AM) is readily capable of producing models and prototypes of complex geometry and is advancing in creating functional parts. However, AM processes typically underperform traditional manufacturing methods in mechanical properties, surface roughness and hermeticity. Solvent vapor treatments (vapor polishing) are commonly used to improve surface quality in thermoplastic parts, but the results are poorly characterized. Design/methodology/approach This work quantifies the surface roughness change and also evaluates the effect on hermeticity and mechanical property impacts for “as-printed” and acetone vapor-polished ABS tensile specimens of 1-, 2- and 4-mm thicknesses produced by material extrusion (FDM). Findings Vapor polishing proves to decrease the power spectral density for surface roughness features larger than 20 µm by a factor of 10× and shows significant improvement in hermeticity based on both perfluorocarbon gross leak and pressure leak tests. However, there is minimal impact on mechanical properties with the thin specimens showing a slight increase in elongation at break but decreased elastic modulus. A bi-exponential diffusion decay model for solvent evaporation suggest a thickness-independent and thickness-dependent time constant with the latter supporting a plasticizing effect on mechanical properties. Originality/value The contributions of this work show vapor polishing can have a substantial impact on the performance for end-use application of ABS FDM components.

Download Full-text

Chances and Limitations in the Application of Laser Chemical Machining for the Manufacture of Micro Forming Dies

MATEC Web of Conferences ◽

10.1051/matecconf/201819015010 ◽

2018 ◽

Vol 190 ◽

pp. 15010 ◽

Cited By ~ 3

Author(s):

Hamza Messaoudi ◽

Florian Böhmermann ◽

Merlin Mikulewitsch ◽

Axel von Freyberg ◽

Andreas Fischer ◽

...

Keyword(s):

Laser Scanning ◽

Dimensional Accuracy ◽

Laser Scanning Confocal Microscopy ◽

Micro Milling ◽

Metallographic Analysis ◽

Manufacturing Processes ◽

Micro Forming ◽

Shape Accuracy ◽

Scanning Confocal Microscopy

Laser chemical machining, a non-conventional processing method based on thermally activated electrochemical material dissolution, represents a promising technology for manufacturing metallic dies for micro forming applications. Prior to widespread industrial acceptance the machining quality of laser chemical machining should be characterized. For this purpose, laser chemical machining is compared with micro milling regarding both the dimensional accuracy and the surface quality. Therefore, square micro cavities exhibiting side walls between 100 μm and 400 μm in length and 60 μm in depth are machined with both manufacturing processes into the cobalt-chrome alloy Stellite 21. The geometrical features are investigated using laser-scanning confocal microscopy and scanning electron microscopy. On the one hand, laser chemical machining is more suitable for manufacturing cavities with dimensions < 200 μm due to higher shape accuracy with stable mean edge radii of (11.2 ± 1.3) μm as a result of roughing and finishing steps. On the other hand, the finish quality of micro milling with mean surface roughness Sa of 0.2 μm could not be achieved with laser chemical machining due to in-process induced waviness. Finally, the metallographic analysis of the surface-near layers reveals that both manufacturing processes ensure gentle machining without any noticeable micro structural impact.

Download Full-text

Parametric Modeling and Compensation of Layer Manufacturing Machines

Materials Science Forum ◽

10.4028/www.scientific.net/msf.797.145 ◽

2014 ◽

Vol 797 ◽

pp. 145-150

Author(s):

Carlos Cajal ◽

Jorge Santolaria ◽

Jesus Velazquez

Keyword(s):

Error Compensation ◽

Kinematic Model ◽

Dimensional Accuracy ◽

Systematic Errors ◽

Parametric Modeling ◽

Manufacturing Processes ◽

3D Printer ◽

Layer Manufacturing ◽

Compensation Technique ◽

Traditional Manufacturing

Layer manufacturing machines are affected, the same way as traditional manufacturing processes, by systematic errors [.This lack of precision and poor dimensional accuracy can be reduced by software compensation techniques. This paper proposes a parametric error compensation technique based on pattern artifacts. This technique is verified on an Objet 350V 3D printer. To begin, these parametric techniques require the development of the machines kinematic model [. The data acquisition is performed with a CMM and a self-centering technique to measure conical sockets manufactured in the faces of pattern artifacts. After manufacturing various test patterns, with and without compensation, the achieved results are close to 80% reduction in mean error.

Download Full-text

Predicting Part Mass, Required Support Material, and Build Time via Autoencoded Voxel Patterns

10.31224/osf.io/8kne7 ◽

2018 ◽

Cited By ~ 3

Author(s):

Christopher McComb ◽

Nicholas Meisel ◽

T. W. Simpson ◽

Christian Murphy

Keyword(s):

Additive Manufacturing ◽

Lightweight Design ◽

Manufacturing Processes ◽

Dimensional Representation ◽

Skill Levels ◽

Experience Levels ◽

Build Time ◽

Machine Learning Applications ◽

Traditional Manufacturing ◽

Low Dimensional

Additive Manufacturing (AM) allows designers to create intricate geometries that were once too complex or expensive to achieve through traditional manufacturing processes. Currently, Design for Additive Manufacturing (DfAM) is restricted to experts in the field, and novices may overlook potentially transformational design potential enabled by AM. This project aims to make DfAM accessible to a broader audience through deep learning, enabling designers of all skill levels to leverage unique AM geometries when creating new designs. To demonstrate such an approach, a database of files was acquired from industry-sponsored AM challenges focused on lightweight design. These files were converted to a voxelized format, which provides more robust information for machine learning applications. Next, an autoencoder was constructed to a low-dimensional representation of the part designs. Finally, that autoencoder was used to construct a deep neural network capable of predicting various DfAM attributes. This work demonstrates a novel foray towards a more extensive DfAM support system that supports designers at all experience levels.

Download Full-text

Optimisation of Strength Properties of FDM Printed Parts—A Critical Review

Polymers ◽

10.3390/polym13101587 ◽

2021 ◽

Vol 13 (10) ◽

pp. 1587

Author(s):

Daniyar Syrlybayev ◽

Beibit Zharylkassyn ◽

Aidana Seisekulova ◽

Mustakhim Akhmetov ◽

Asma Perveen ◽

...

Keyword(s):

Mechanical Properties ◽

Layer Thickness ◽

Process Parameters ◽

Fused Deposition Modeling ◽

Complex Geometry ◽

Positive Impact ◽

Dimensional Accuracy ◽

Strength Properties ◽

Fused Filament Fabrication ◽

Fused Deposition

Additive Manufacturing is currently growing fast, especially fused deposition modeling (FDM), also known as fused filament fabrication (FFF). When manufacturing parts use FDM, there are two key parameters—strength of the part and dimensional accuracy—that need to be considered. Although FDM is a popular technology for fabricating prototypes with complex geometry and other part product with reduced cycle time, it is also limited by several drawbacks including inadequate mechanical properties and reduced dimensional accuracy. It is evident that part qualities are greatly influenced by the various process parameters, therefore an extensive review of the effects of the following process parameters was carried out: infill density, infill patterns, extrusion temperature, layer thickness, nozzle diameter, raster angle and build orientation on the mechanical properties. It was found from the literature that layer thickness is the most important factor among the studied ones. Although manipulation of process parameters makes significant differences in the quality and mechanical properties of the printed part, the ideal combination of parameters is challenging to achieve. Hence, this study also includes the influence of pre-processing of the printed part to improve the part strength and new research trends such as, vacuum-assisted FDM that has shown to improve the quality of the printing due to improved bonding between the layers. Advances in materials and technologies that are currently under development are presented. For example, the pre-deposition heating method, using an IR lamp of other technologies, shows a positive impact on the mechanical properties of the printed parts.

Download Full-text

Removal behavior and output quality for laser chemical machining of tool steels

Manufacturing Review ◽

10.1051/mfreview/2019015 ◽

2019 ◽

Vol 6 ◽

pp. 13 ◽

Cited By ~ 1

Author(s):

Hamza Messaoudi ◽

Merlin Mikulewitsch ◽

Daniel Brand ◽

Axel von Freyberg ◽

Andreas Fischer

Keyword(s):

Surface Roughness ◽

High Speed ◽

High Speed Steel ◽

Dimensional Accuracy ◽

Micro Milling ◽

Machining Processes ◽

Shape Accuracy ◽

Stellite 21 ◽

Micro Parts ◽

Subtractive Machining

Laser chemical machining represents a promising technology for manufacturing metallic micro parts. It is usually based on the selective thermal activation of electrochemical material dissolution of self-passivating metals in an electrolyte environment. Prior to widespread industrial acceptance, its machining quality needs to be classified within the subtractive machining processes and the range of machinable materials needs to be expanded. For this purpose, line and square cavities with dimensions ≤300 μm are machined into high speed steel HS10-4-3-10 in a H3PO4-environment and compared to those of the self-passivating cobalt-chrome alloy Stellite 21. As a result, the laser-induced removal velocities in HS10-4-3-10 amount to 50 μm/s. These are two orders of magnitudes higher than the background etching (2 nm/s at room temperature) and three times higher than those obtained in Stellite 21 (12 μm/s). However, the microscopic and spectroscopic analyses of both materials reveal a high shape accuracy with edge radii from 10 to 20 μm, a surface roughness down to 0.8 μm and a negligible microstructural impact. Despite lower removal rates and higher surface roughness, laser chemical machining provides higher dimensional accuracy in comparison with micro milling and shows its suitability for micro machining of structures <200 μm.

Download Full-text

Metal Machining—Recent Advances, Applications, and Challenges

Metals ◽

10.3390/met11040580 ◽

2021 ◽

Vol 11 (4) ◽

pp. 580

Author(s):

Francisco J. G. Silva

Keyword(s):

Surface Finish ◽

Manufacturing Process ◽

Dimensional Accuracy ◽

Machining Process ◽

High Dimensional ◽

Manufacturing Processes ◽

Recent Advances ◽

Metal Machining ◽

Rapid Manufacture

Though new manufacturing processes that revolutionize the landscape regarding the rapid manufacture of parts have recently emerged, the machining process remains alive and up-to-date in this context, always presenting itself as a manufacturing process with several variants and allowing for high dimensional accuracy and high levels of surface finish [...]

Download Full-text

Study on mechanical properties of a new type of prefabricated GRC mold shell

E3S Web of Conferences ◽

10.1051/e3sconf/201913602030 ◽

2019 ◽

Vol 136 ◽

pp. 02030

Author(s):

Chen Dong ◽

Chen Ming ◽

Cai Ouyang ◽

Li Pengkun

Keyword(s):

Mechanical Properties ◽

Production Process ◽

Cross Section ◽

Stress System ◽

Research Results ◽

Floor Space ◽

Section Size ◽

Speed Up ◽

New Type ◽

Prefabricated Building

The GRC formwork structural column adopts the factory-based vertical prefabrication production process, which can reduce the floor space, reduce the formwork loss, speed up the construction progress, promote the full decoration of the prefabricated building, and improve the efficiency of the assembly construction. major. In order to optimize the production process of prefabricated GRC formwork column, the overall stress system of GRC formwork structure is analyzed in the concrete pouring process, and the thickness of GRC formwork, the number of steel hoops and the GRC mode are considered. The influence of the shell cross-section size on the mechanical properties. The research results can provide reference for the optimization and design of prefabricated GRC formwork column production process.

Download Full-text