scholarly journals Review on additive hybrid- and multi-material-manufacturing of metals by powder bed fusion: state of technology and development potential

2021 ◽  
Author(s):  
M. Schneck ◽  
M. Horn ◽  
M. Schmitt ◽  
C. Seidel ◽  
G. Schlick ◽  
...  
Keyword(s):  
Review Paper ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Data Preparation ◽  
Powder Bed ◽  
Theoretical Approaches ◽  
Powder Deposition ◽  
Readiness Level ◽  
Manufacturing Readiness ◽  
2D And 3D

AbstractIn this review paper, the authors investigate the state of technology for hybrid- and multi-material (MM) manufacturing of metals utilizing additive manufacturing, in particular powder bed fusion processes. The study consists of three parts, covering the material combinations, the MM deposition devices, and the implications in the process chain. The material analysis is clustered into 2D- and 3D-MM approaches. Based on the reviewed literature, the most utilized material combination is steel-copper, followed by fusing dissimilar steels. Second, the MM deposition devices are categorized into holohedral, nozzle-based as well as masked deposition concepts, and compared in terms of powder deposition rate, resolution, and manufacturing readiness level (MRL). As a third aspect, the implications in the process chain are investigated. Therefore, the design of MM parts and the data preparation for the production process are analyzed. Moreover, aspects for the reuse of powder and finalization of MM parts are discussed. Considering the design of MM parts, there are theoretical approaches, but specific parameter studies or use cases are not present in the literature. Principles for powder separation are identified for exemplary material combinations, but results for further finalization steps of MM parts have not been found. In conclusion, 3D-MM manufacturing has a MRL of 4–5, which indicates that the technology can be produced in a laboratory environment. According to this maturity, several aspects for serial MM parts need to be developed, but the potential of the technology has been demonstrated. Thus, the next important step is to identify lead applications, which benefit from MM manufacturing and hence foster the industrialization of these processes.

scholarly journals Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component

Metals ◽  
2021 ◽  
Vol 12 (1) ◽  
pp. 44
Author(s):  
Matthias Schneck ◽  
Max Horn ◽  
Maik Schindler ◽  
Christian Seidel
Keyword(s):  
Technology Development ◽  
Three Dimensional ◽  
Functionally Graded ◽  
Powder Bed Fusion ◽  
Material Technology ◽  
Fusion Development ◽  
Powder Bed ◽  
Local Product ◽  
Readiness Level ◽  
Manufacturing Readiness

Additive Manufacturing (AM) allows the manufacturing of functionally graded materials (FGM). This includes compositional grading, which enables the allocation of desired materials corresponding to local product requirements. An upcoming AM process for the creation of metal-based FGMs is laser-based powder bed fusion (PBF-LB/M) utilized for multi-material manufacturing (MM). Three-dimensional multi-material approaches for PBF-LB/M are stated to have a manufacturing readiness level (MRL) of 4 to 5. In this paper, an advancement of multi-material technology is presented by realizing an industry-relevant complex part as a prototype made by PBF-LB/M. Hence, a multi-material injection nozzle consisting of tool steel and a copper alloy was manufactured in a continuous PBF-LB/M process. Single material regions showed qualities similar to the ones resulting from mono-material processes. A geometrically defined transition zone between the two materials was achieved that showed slightly higher porosity than mono-material regions. Nevertheless, defects such as porosity, cracks, and material cross-contamination were detected and must be overcome in further MM technology development.

Hybride Fertigung mittels Laser-Strahlschmelzen/Hybrid manufacturing by laser-based powder bed fusion

2021 ◽  
Vol 111 (06) ◽  
pp. 363-367
Author(s):  
Lukas Langer ◽  
Matthias Schmitt ◽  
Georg Schlick ◽  
Johannes Schilp
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Processes ◽  
Complex Geometries ◽  
Hybrid Manufacturing ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Manufacturing Costs ◽  
Additive Fertigung ◽  
Powder Bed

Die additive Fertigung ermöglicht komplexe Geometrien und individualisierte Bauteile. Die hohen Material- und Fertigungskosten können ein Hindernis für einen wirtschaftlichen Einsatz sein. In der hybriden additiven Fertigung werden die Vorteile konventioneller sowie additiver Fertigungsverfahren kombiniert. Für eine weitere Steigerung der Wirtschaftlichkeit und Effizienz werden nichtwertschöpfende Schritte der Prozesskette identifiziert und Automatisierungsansätze entwickelt.   Additive manufacturing enables complex geometries and individualized components. However, high material and manufacturing costs can be a hindrance for economical use. Hybrid additive manufacturing combines the advantages of conventional with additive manufacturing processes. For a further increase in profitability and efficiency, non-value-adding steps in the process chain are identified and automation approaches developed.

scholarly journals Nanoparticle Additivation Effects on Laser Powder Bed Fusion of Metals and Polymers—A Theoretical Concept for an Inter-Laboratory Study Design All Along the Process Chain, Including Research Data Management

Materials ◽  
2021 ◽  
Vol 14 (17) ◽  
pp. 4892
Author(s):  
Ihsan Murat Kusoglu ◽  
Florian Huber ◽  
Carlos Doñate-Buendía ◽  
Anna Rosa Ziefuss ◽  
Bilal Gökce ◽  
...  
Keyword(s):  
Research Data ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Research Data Management ◽  
Polymer Powder ◽  
Powder Feedstock ◽  
Repeatability And Reproducibility ◽  
Material Process

In recent years, the application field of laser powder bed fusion of metals and polymers extends through an increasing variability of powder compositions in the market. New powder formulations such as nanoparticle (NP) additivated powder feedstocks are available today. Interestingly, they behave differently along with the entire laser powder bed fusion (PBF-LB) process chain, from flowability over absorbance and microstructure formation to processability and final part properties. Recent studies show that supporting NPs on metal and polymer powder feedstocks enhances processability, avoids crack formation, refines grain size, increases functionality, and improves as-built part properties. Although several inter-laboratory studies (ILSs) on metal and polymer PBF-LB exist, they mainly focus on mechanical properties and primarily ignore nano-additivated feedstocks or standardized assessment of powder feedstock properties. However, those studies must obtain reliable data to validate each property metric’s repeatability and reproducibility limits related to the PBF-LB process chain. We herein propose the design of a large-scale ILS to quantify the effect of nanoparticle additivation on powder characteristics, process behavior, microstructure, and part properties in PBF-LB. Besides the work and sample flow to organize the ILS, the test methods to measure the NP-additivated metal and polymer powder feedstock properties and resulting part properties are defined. A research data management (RDM) plan is designed to extract scientific results from the vast amount of material, process, and part data. The RDM focuses not only on the repeatability and reproducibility of a metric but also on the FAIR principle to include findable, accessible, interoperable, and reusable data/meta-data in additive manufacturing. The proposed ILS design gives access to principal component analysis (PCA) to compute the correlations between the material–process–microstructure–part properties.

scholarly journals Numerical Investigation into the Effect of Different Parameters on the Geometrical Precision in the Laser-Based Powder Bed Fusion Process Chain

2020 ◽  
Vol 10 (10) ◽  
pp. 3414
Author(s):  
David De Baere ◽  
Mandanà Moshiri ◽  
Sankhya Mohanty ◽  
Guido Tosello ◽  
Jesper Henri Hattel
Keyword(s):  
Heat Treatment ◽  
Stress Relaxation ◽  
Heat Treatment Temperature ◽  
Base Plate ◽  
Treatment Temperature ◽  
Chain Model ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Post Processing ◽  
Powder Bed

Due to the layer-by-layer nature of the process, parts produced by laser-based powder bed fusion (LPBF) have high residual stresses, causing excessive deformations. To avoid this, parts are often post-processed by subjecting them to specially designed heat treatment cycles before or after their removal from the base plate. In order to investigate the effects of the choice of post-processing steps, in this work the entire LPBF process chain is modelled in a commercial software package. The developed model illustrates the possibilities of implementing and tailoring the process chain model for metal additive manufacturing using a general purpose finite element (FE) solver. The provided simplified computational example presents an idealised model to analyse the validity of implementing the LPBF process chain in FE software. The model is used to evaluate the effect of the order of the process chain, the heat treatment temperature and the duration of the heat treatment. The results show that the model is capable of qualitatively capturing the effect of the stress relaxation that occurs during a heat treatment at elevated temperature. Due to its implementation, the model is relatively insensitive to duration and heat treatment temperature, at least as long as it is above the relaxation temperature. Furthermore, the simulations suggest that, when post-processing, it is necessary to perform the stress relaxation before the part is removed from the base plate, in order to avoid a significant increase of the deformation. The paper demonstrates the capability of the simulation tool to evaluate the effects of variations in the process chain steps and highlights its potential usage in directing decision-making for LPBF process chain design.

scholarly journals Effects on the distortion of Inconel 718 components along a hybrid laser-based additive manufacturing process chain using laser powder bed fusion and laser metal deposition

2021 ◽  
Author(s):  
Eckart Uhlmann ◽  
Jan Düchting ◽  
Torsten Petrat ◽  
Erwin Krohmer ◽  
Benjamin Graf ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Inconel 718 ◽  
Powder Bed Fusion ◽  
Laser Metal Deposition ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Plate Material ◽  
Powder Bed ◽  
Manufacturing Process Chain

AbstractThe combination of laser powder bed fusion (LPBF), known for its geometrical freedom and accuracy, and the nozzle-based laser metal deposition process (LMD), known for its high build-up rates, has great potential to reduce the additive manufacturing times for large metallic parts. For the industrial application of the LPBF-LMD hybrid process chain, it is necessary to investigate the influence of the LMD process on the LPBF substrate. In addition, the build plate material also has a significant impact on the occurrence of distortion along the additive manufacturing process chain. In the literature, steel build plates are often used in laser-based additive manufacturing processes of Inconel 718, since a good metallurgical bonding can be assured whilst reducing costs in the production and restoration of the build plates. This paper examines the distortion caused by LMD material deposition and the influence of the build plate material along the hybrid additive manufacturing process chain. Twin cantilevers are manufactured by LPBF and an additional layer is subsequently deposited with LMD. The distortion is measured in the as-built condition as well as after heat treatment. The effect of different LMD hatch strategies on the distortion is determined. The experiments are conducted using the nickel-base alloy Inconel 718. The results show a significant influence of LMD path strategies on distortion, with shorter tool paths leading to less distortion. The remaining distortion after heat treatment is considerably dependent on the material of the build plate.

scholarly journals Sustainable Aspects of a Metal Printing Process Chain with Laser Powder Bed Fusion (LPBF)

Procedia CIRP ◽  
2021 ◽  
Vol 98 ◽  
pp. 613-618
Author(s):  
Dennis Ochs ◽  
Kira Kristin Wehnert ◽  
Jürgen Hartmann ◽  
Andreas Schiffler ◽  
Jan Schmitt
Keyword(s):  
Powder Bed Fusion ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Printing Process ◽  
Powder Bed ◽  
Metal Printing

scholarly journals Maturity Assessment of Laser Powder Bed Fusion Process Chain Modelling and Simulation

2021 ◽  
pp. 34-45
Author(s):  
Anas Yaghi ◽  
Shukri Afazov ◽  
Matteo Villa
Keyword(s):  
Case Studies ◽  
Manufacturing Process ◽  
Modelling And Simulation ◽  
Fusion Process ◽  
Design Solution ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Process Chains

This paper presents case studies of additive manufacturing process chains including laser powder bed fusion and post-processes. The presented case studies are used to assess the maturity of the manufacturing process chains using a Modelling and Simulation Readiness Level Scale. The results from the assessment have shown that the maturity of the modelling and simulation of laser powder bed fusion process chains lies between the stage of applied research and development and the stage of being instrumental, with high reliance on modelling and simulation experts. This means that the laser powder bed fusion (L-PBF) process chain modelling and simulation can support low-risk development, with high reliance on modelling and simulation experts, making them suitable for qualitative assessment, alternative design/solution ranking, defining the design structure, constraining the design space and replacing some experimental trials. This shows that further maturation is required before the modelling and simulation methods and codes are well recognised as best practice in the industry and are part of operational process control at any stage of the supply chain.

Sign in / Sign up

Export Citation Format

Share Document