scholarly journals Build Orientation Determination for Multi-material Deposition Additive Manufacturing with Continuous Fibers

Procedia CIRP ◽  
2016 ◽  
Vol 50 ◽  
pp. 414-419 ◽  
Author(s):  
Yicha Zhang ◽  
Wout De Backer ◽  
Ramy Harik ◽  
Alain Bernard
Keyword(s):  
Additive Manufacturing ◽  
Build Orientation ◽  
Material Deposition ◽  
Orientation Determination

A statistical method for build orientation determination in additive manufacturing

2019 ◽  
Vol 25 (1) ◽  
pp. 187-207 ◽  
Author(s):  
Yicha Zhang ◽  
Ramy Harik ◽  
Georges Fadel ◽  
Alain Bernard
Keyword(s):  
Additive Manufacturing ◽  
Statistical Method ◽  
Supervised Machine Learning ◽  
Surface Model ◽  
Generic Level ◽  
Content Type ◽  
Build Orientation ◽  
Cad Models ◽  
Feature Based ◽  
Orientation Determination

Purpose For part models with complex shape features or freeform shapes, the existing build orientation determination methods may have issues, such as difficulty in defining features and costly computation. To deal with these issues, this paper aims to introduce a new statistical method to develop fast automatic decision support tools for additive manufacturing build orientation determination. Design/methodology/approach The proposed method applies a non-supervised machine learning method, K-Means Clustering with Davies–Bouldin Criterion cluster measuring, to rapidly decompose a surface model into facet clusters and efficiently generate a set of meaningful alternative build orientations. To evaluate alternative build orientations at a generic level, a statistical approach is defined. Findings A group of illustrative examples and comparative case studies are presented in the paper for method validation. The proposed method can help production engineers solve decision problems related to identifying an optimal build orientation for complex and freeform CAD models, especially models from the medical and aerospace application domains with much efficiency. Originality/value The proposed method avoids the limitations of traditional feature-based methods and pure computation-based methods. It provides engineers a new efficient decision-making tool to rapidly determine the optimal build orientation for complex and freeform CAD models.

scholarly journals Investigation of High-Depostition-Rate Additive Manufacturing of Ti-6Al-4V via Laser Material Deposition

2021 ◽  
Author(s):  
Rebar Hama-Saleh ◽  
Kerim Yildirim ◽  
Susanne Hemes ◽  
Andreas Weisheit ◽  
Constantin Leon Häfner
Keyword(s):  
Additive Manufacturing ◽  
Hot Forging ◽  
Scanning Speed ◽  
Inert Atmosphere ◽  
High Deposition Rate ◽  
Beam Diameter ◽  
Deposition Rates ◽  
Laser Material ◽  
Aerospace Applications ◽  
Material Deposition

Ti-6Al-4V is the most prominent titanium alloy widely used e.g. for aerospace applications. Conventionally, many Ti-6Al-4V aerospace components are produced by a multi-stage hot forging process followed by subsequent machining which often generates a high amount of scrap. Additive manufacturing (AM), such as powder-based laser material deposition (p-LMD), enables parts to be made with geometric freedom and near-net-shape, but so far lacks high deposition rates. The present study proposes high-deposition-rate laser material deposition manufacturing using a large laser beam diameter and increased scanning speed to achieve deposition rates up to 5 kg/h. As Ti-6Al-4V is prone to oxygen pick-up, the process was performed in an inert atmosphere. We determined suitable process windows for tracks without fusion defects and low porosity and investigated microstructure and hardness.

Additive manufacturing of 316L stainless-steel structures using fused filament fabrication technology: mechanical and geometric properties

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Miguel Ángel Caminero ◽  
Ana Romero ◽  
Jesús Miguel Chacón ◽  
Pedro José Núñez ◽  
Eustaquio García-Plaza ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Austenitic Stainless Steel ◽  
Material Properties ◽  
Steel Structures ◽  
Fused Filament Fabrication ◽  
Geometric Properties ◽  
Content Type ◽  
Build Orientation ◽  
Manufacturing Alternatives

Purpose Fused filament fabrication (FFF) technique using metal filled filaments in combination with debinding and sintering steps can be a cost-effective alternative for laser-based powder bed fusion processes. The mechanical behaviour of FFF-metal materials is highly dependent on the processing parameters, filament quality and adjusted post-processing steps. In addition, the microstructural material properties and geometric characteristics are inherent to the manufacturing process. The purpose of this study is to characterize the mechanical and geometric performance of three-dimensional (3-D) printed FFF 316 L metal components manufactured by a low-cost desktop 3-D printer. The debinding and sintering processes are carried out using the BASF catalytic debinding process in combination with the BASF 316LX Ultrafuse filament. Special attention is paid on the effects of build orientation and printing strategy of the FFF-based technology on the tensile and geometric performance of the 3-D printed 316 L metal specimens. Design/methodology/approach This study uses a toolset of experimental analysis techniques [metallography and scanning electron microcope (SEM)] to characterize the effect of microstructure and defects on the material properties under tensile testing. Shrinkage and the resulting porosity of the 3-D printed 316 L stainless steel sintered samples are also analysed. The deformation behaviour is investigated for three different build orientations. The tensile test curves are further correlated with the damage surface using SEM images and metallographic sections to present grain deformation during the loading progress. Mechanical properties are directly compared to other works in the field and similar additive manufacturing (AM) and Metal Injection Moulding (MIM) manufacturing alternatives from the literature. Findings It has been shown that the effect of build orientation was of particular significance on the mechanical and geometric performance of FFF-metal 3-D printed samples. In particular, Flat and On-edge samples showed an average increase in tensile performance of 21.7% for the tensile strength, 65.1% for the tensile stiffness and 118.3% for maximum elongation at fracture compared to the Upright samples. Furthermore, it has been able to manufacture near-dense 316 L austenitic stainless steel components using FFF. These properties are comparable to those obtained by other metal conventional processes such as MIM process. Originality/value 316L austenitic stainless steel components using FFF technology with a porosity lower than 2% were successfully manufactured. The presented study provides more information regarding the dependence of the mechanical, microstructural and geometric properties of FFF 316 L components on the build orientation and printing strategy.

Automated Geometric Correction System for Additive Manufacturing Considering Build Orientation

2021 ◽  
pp. 1-30
Author(s):  
Seyedeh Elaheh Ghiasian ◽  
Kemper Lewis
Keyword(s):  
Additive Manufacturing ◽  
Optimization Model ◽  
Experimental Validation ◽  
Minimal Amount ◽  
Feature Size ◽  
Build Orientation ◽  
Computational Performance ◽  
The Difference ◽  
Processing Effort ◽  
Correction System

Abstract One of the current challenges for the additive manufacturing (AM) industry lies in providing component designs compatible with the AM manufacturability and constraints without compromising the component structural functionalities. To address this challenge, we present an automated correction system that provides geometrically feasible designs for additive processes by applying locally effective modifications while avoiding substantial changes in the current designs. Considering a minimum printable feature size from the process parameters, this system identifies the problematic features in an infeasible part's design using a holistic geometric assessment algorithm. Based on the obtained manufacturability feedback, the system then corrects the detected problematic regions using a set of appropriate redesign solutions through an automated procedure. In addition, to reduce the difference between the current and modified part geometries, a novel optimization model for build orientation is presented. Using this model, one can identify appropriate orientations for obtaining a feasible design with a minimal amount of corrections while also reducing the post-processing effort by minimizing the area of contact with the support structure. The functionalities of the presented correction system and the optimization model are illustrated using a number of case studies with varying geometries. The computational performance of the system and an experimental validation are also presented to demonstrate the effectiveness of the implemented detection and modification approaches.

scholarly journals Investigating the Mechanics of Hybrid Metal Extrusion and Bonding Additive Manufacturing by FEA

Metals ◽  
2019 ◽  
Vol 9 (8) ◽  
pp. 811 ◽  
Author(s):  
Jørgen Blindheim ◽  
Torgeir Welo ◽  
Martin Steinert
Keyword(s):  
Additive Manufacturing ◽  
Material Flow ◽  
Deposition Process ◽  
Feed Speed ◽  
Element Analysis ◽  
Reduced Pressure ◽  
Metal Structures ◽  
Material Deposition ◽  
Flow Through ◽  
Metal Extrusion

Hybrid Metal Extrusion & Bonding Additive Manufacturing (HYB-AM) is a hybrid manufacturing technology for the deposition of layered metal structures. This new deposition process is a complex metal forming operation, yet there is significant lack of knowledge regarding the governing mechanisms. In this work, we have used finite element analysis (FEA) to study material flow in the extruder, as well as the conditions at the interfaces of the deposited extrudate and the substrate, aiming to identify and characterize the process parameters involved. Analysis of the material flow shows that the extrusion pressure is virtually independent of the deposition rate. Furthermore, from the simulations of the material deposition sequence, it is clearly visible how the contact pressure at the interface will drop below the bonding threshold if the feed speed is too high relative to the material flow through the die. The reduced pressure also leads to the formation of a ‘gas-pocket’ inside the die, thus further degrading the conditions for bonding. The analyses of the process have provided valuable insights for the further development and industrialization of the process.

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