scholarly journals An Overview of Cold Spray Additive Technology in Australia for Melt-less Manufacture of Titanium

2020 ◽  
Vol 321 ◽  
pp. 03011
Author(s):  
Saden H. Zahiri ◽  
Stefan Gulizia ◽  
Leon Prentice
Keyword(s):  
Additive Manufacturing ◽  
Solid State ◽  
Cold Spray ◽  
Melting Process ◽  
3D Models ◽  
Environmental Benefits ◽  
High Deposition Rate ◽  
Commercial Applications ◽  
The Cost ◽  
Traditional Approaches

The difficulty in significantly reducing the cost of titanium products is partly related to the high cost of manufacturing. This includes additive manufacturing; e.g. Electron Beam Melting (EBM) and Selective Laser Melting (SLM), as well as traditional approaches that are based on a melting process. In particular, the cost of titanium powder has placed limits on the application of additive manufacturing approaches that involve melting to broader commercial applications beyond military, aerospace and implants. More than a decade ago, Australia adopted cold spray technology as a meltless additive manufacturing technique to fabricate titanium through a strategic initiative at Commonwealth Scientific and Industrial Research Organisation (CSIRO). The high deposition rate, ~100 times faster than the other additive technologies, and the solid state deposition were amongst the rationales for investment in cold spray technology. A combination of carefully designed experiments and sophisticated 3D models were developed to assess performance of the current industrial-scale cold spray systems for commercial clients. The success and challenges of this solid state deposition technology will be detailed with a focus on real industrial impact. The future development of melt-less titanium manufacturing using cold spray will be discussed with consideration of commercial and environmental benefits.

A Study of Life Cycle Costing in the Perspectives of Research and Commercial Applications in the 21st Century

2007 ◽  
Author(s):  
Wai M. Cheung ◽  
Linda B. Newnes ◽  
Antony R. Mileham ◽  
Robert Marsh ◽  
John D. Lanham
Keyword(s):  
Life Cycle ◽  
Cost Estimation ◽  
Life Cycle Cost ◽  
Academic Research ◽  
Life Cycle Costing ◽  
Electronic Products ◽  
Commercial Applications ◽  
The Uk ◽  
The Cost ◽  
Traditional Approaches

This paper presents a review of research in the area of life cycle costing and offers a critique of current commercial cost estimation systems. The focus of the review is on relevant academic research on life cycle cost from 2000 onwards. In addition to this a comparison of the current cost estimation systems is presented. Using the review findings and industrial investigations as a base, a set of mathematical representations for design and manufacturing costs and the introduction of the critical factors is proposed. These are considered in terms of the operational, maintenance and disposal costs to create a method for ascertaining the life cycle cost estimate for complex products. This is presented using as an exemplar, research currently being undertaken in the area of low volume and long life electronic products in the UK defence sector. The benefit of the method proposed is that it aims to avoid the inflexibility of traditional approaches which usually require historical and legacy data to support the cost estimation processes.

scholarly journals Novel Characterization Techniques for Additive Manufacturing Powder Feedstock

Metals ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 720
Author(s):  
Benjamin Young ◽  
Joseph Heelan ◽  
Sean Langan ◽  
Matthew Siopis ◽  
Caitlin Walde ◽  
...  
Keyword(s):  
Quality Control ◽  
Additive Manufacturing ◽  
Solid State ◽  
Cold Spray ◽  
Metal Powders ◽  
Characterization Methods ◽  
Powder Feedstock ◽  
Additive Methods

Additive manufacturing is a rapidly expanding field, encompassing many methods to manufacture parts and coatings with a wide variety of feedstock. Metal powders are one such feedstock, with a range of compositions and morphologies. Understanding subtle changes in the feedstock is critical to ensure successful consolidation and quality control of both the feedstock and manufactured part. Current standards lack the ability to finely distinguish almost acceptable powders from barely acceptable ones. Here, novel means of powder feedstock characterization for quality control are demonstrated for the solid-state AM process of cold spray, though similar methods may be extrapolated to other additive methods as well. These characterization methods aim to capture the physics of the process, which in cold spray consists of high strain rate deformation of solid-state feedstock. To capture this, in this effort powder compaction was evaluated via rapidly applied loads, flowability of otherwise non-flowable powders was evaluated with the addition of vibration, and powder electrical resistivity was evaluated through compaction between two electrodes. Several powders, including aluminum alloys, chromium, and cermet composites, were evaluated in this effort, with each case study demonstrating the need for non-traditional characterization metrics as a means of quality control and classification of these materials.

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

2021 ◽  
pp. 095440622199840
Author(s):  
Yashwant Koli ◽  
N Yuvaraj ◽  
Aravindan Sivanandam ◽  
Vipin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Large Scale ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Geometrical Shapes ◽  
Wire Arc Additive Manufacturing

Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

scholarly journals Improving surface quality in selective laser melting based tool making

2021 ◽  
Author(s):  
Filippo Simoni ◽  
Andrea Huxol ◽  
Franz-Josef Villmer
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Melting Process ◽  
Laser Remelting ◽  
Laser Melting ◽  
Great Cost ◽  
Starting Point ◽  
Processing Techniques

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.

3D modelling of the deposit profile in cold spray additive manufacturing

2021 ◽  
Vol 67 ◽  
pp. 521-534
Author(s):  
Daniele Vanerio ◽  
Jan Kondas ◽  
Mario Guagliano ◽  
Sara Bagherifard
Keyword(s):  
Additive Manufacturing ◽  
Cold Spray ◽  
3D Modelling

scholarly journals An Additively Manufactured Titanium Alloy in the Focus of Metallography

2021 ◽  
Vol 58 (1) ◽  
pp. 4-31
Author(s):  
C. Fleißner-Rieger ◽  
T. Pogrielz ◽  
D. Obersteiner ◽  
T. Pfeifer ◽  
H. Clemens ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Microstructural Analysis ◽  
Microstructural Characterization ◽  
Melting Process ◽  
Manufacturing Processes ◽  
Ingot Metallurgy ◽  
Lightweight Structures ◽  
Metallographic Preparation ◽  
Fine Structures ◽  
Specific Material

Abstract Additive manufacturing processes allow the production of geometrically complex lightweight structures with specific material properties. However, by contrast with ingot metallurgy methods, the manufacture of components using this process also brings about some challenges. In the field of microstructural characterization, where mostly very fine structures are analyzed, it is thus indispensable to optimize the classic sample preparation process and to furthermore implement additional preparation steps. This work focuses on the metallography of additively manufactured Ti‑6Al‑4V components produced in a selective laser melting process. It offers a guideline for the metallographic preparation along the process chain of additive manufacturing from the metal powder characterization to the macro- and microstructural analysis of the laser melted sample. Apart from developing preparation parameters, selected etching methods were examined with regard to their practicality.

scholarly journals Longevity of Raw and Lyophilized Crude Urease Extracts

2021 ◽  
Vol 2 (2) ◽  
pp. 325-334
Author(s):  
Neda Javadi ◽  
Hamed Khodadadi Tirkolaei ◽  
Nasser Hamdan ◽  
Edward Kavazanjian
Keyword(s):  
Crude Extract ◽  
Room Temperature ◽  
Low Cost ◽  
Extraction Process ◽  
Crude Extracts ◽  
Simple Extraction ◽  
Commercial Applications ◽  
Stable Source ◽  
The Stability ◽  
The Cost

The stability (longevity of activity) of three crude urease extracts was evaluated in a laboratory study as part of an effort to reduce the cost of urease for applications that do not require high purity enzyme. A low-cost, stable source of urease will greatly facilitate engineering applications of urease such as biocementation of soil. Inexpensive crude extracts of urease have been shown to be effective at hydrolyzing urea for carbonate precipitation. However, some studies have suggested that the activity of a crude extract may decrease with time, limiting the potential for its mass production for commercial applications. The stability of crude urease extracts shown to be effective for biocementation was studied. The crude extracts were obtained from jack beans via a simple extraction process, stored at room temperature and at 4 ℃, and periodically tested to evaluate their stability. To facilitate storage and transportation of the extracted enzyme, the longevity of the enzyme following freeze drying (lyophilization) to reduce the crude extract to a powder and subsequent re-hydration into an aqueous solution was evaluated. In an attempt to improve the shelf life of the lyophilized extract, dextran and sucrose were added during lyophilization. The stability of purified commercial urease following rehydration was also investigated. Results of the laboratory tests showed that the lyophilized crude extract maintained its activity during storage more effectively than either the crude extract solution or the rehydrated commercial urease. While incorporating 2% dextran (w/v) prior to lyophilization of the crude extract increased the overall enzymatic activity, it did not enhance the stability of the urease during storage.

Fabrication of circular cooling channels by cold metal transfer based wire and arc additive manufacturing

2021 ◽  
pp. 095440542199561
Author(s):  
Shaohua Han ◽  
Zhongzhong Zhang ◽  
Pengxiang Ruan ◽  
Shiwen Cheng ◽  
Dingqi Xue
Keyword(s):  
Additive Manufacturing ◽  
High Energy ◽  
Cooling Effect ◽  
High Deposition Rate ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Energy Beam ◽  
Cooling Channels ◽  
Straight Line

Additive manufacturing has been proven to be a promising technology for fabricating high-performance dies, molds, and conformal cooling channels. As one of the manufacturing methods, wire and arc additive manufacturing displays unique advantages of low cost and high deposition rate that are better than other high energy beam-based ones. This paper presents a preliminary study of fabricating integrated cooling channels by CMT-based wire and arc additive manufacturing process. The deposition strategies for fabricating circular cross-sectional cooling channels both in conformal and straight-line patterns have been investigated. It included optimizing the welding torch angle, fabricating the enclosed semicircle structure and predicting the collision between the torch and constructed part. The cooling effect test was also conducted on both the conformal cooling channel and straight-line cooling channel. The results affirmed a higher cooling efficiency and better uniform cooling effect of the conformal cooling channel than straight-line cooling channel.

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