Rapid Manufacturing by Laser Aided Direct Metal Deposition Process: Issues and Examples

2001 ◽  
Author(s):  
J. Choi ◽  
J. Mazumder
Keyword(s):  
New Product ◽  
Deposition Process ◽  
Effective Control ◽  
Rapid Manufacturing ◽  
Layer By Layer ◽  
Metal Component ◽  
Detail Design ◽  
Melt Pool ◽  
Material Deposition ◽  
Rapid Production

Abstract Development of a new product takes several phases — conceptual design, assembly layouts, detail design, prototype, testing, and then production. Competitiveness hinges on reducing these phases in time for new products. Rapid prototyping (RP) and rapid production are the concept that is aimed specifically at that goal. The essence of RP and rapid production is the formation of a solid 3-D object directly from CAD dimensions. Laser aided direct metal/material deposition (LADMD) offers the ability to make a metal component directly from 3-D CAD dimensions. 3-D CAD data can be converted to machine tool code after the 3-D object is sliced down layer by layer. Repeating laser cladding pass layer by layer, a 3-D object can be formed with the help of CAD data. The key of this build-up mechanism is the effective control of powder to be delivered and laser power to be irradiated into the melt-pool. Adaptive deposition associated with varied thickness deposition is more effective to build up layers quickly than uniform thickness deposition. The rational for this deposition strategy is how quickly and how soundly it can be deposited. Fabricated example parts are presented. This paper also reviews important issues regarding geometrical integrity as well as material integrity in developing LADMD process.

scholarly journals Evaluation of the relevance of melt pool dynamics in Laser Material Deposition process modeling

2017 ◽  
Vol 115 ◽  
pp. 80-91 ◽  
Author(s):  
Jon Iñaki Arrizubieta ◽  
Aitzol Lamikiz ◽  
Fritz Klocke ◽  
Silvia Martínez ◽  
Kristian Arntz ◽  
...  
Keyword(s):  
Process Modeling ◽  
Deposition Process ◽  
Laser Material ◽  
Melt Pool ◽  
Material Deposition

Evaluation of efficiency and mechanical properties of Inconel 718 components built by wire and powder laser material deposition

2017 ◽  
Vol 23 (6) ◽  
pp. 965-972 ◽  
Author(s):  
Jon Iñaki Arrizubieta ◽  
Fritz Klocke ◽  
Nils Klingbeil ◽  
Kristian Arntz ◽  
Aitzol Lamikiz ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Inconel 718 ◽  
Deposition Process ◽  
Tensile Tests ◽  
Ultimate Tensile Stress ◽  
Layer By Layer ◽  
Laser Material ◽  
Content Type ◽  
Material Deposition ◽  
Process Reliability

Purpose The purpose of this paper is to evaluate and compare powder and wire laser material deposition (LMD) processes. Design/methodology/approach In the present paper, Inconel 718 tensile test probes were built layer by layer using a longitudinal strategy, and the quality of the deposited material was characterized for both wire and powder LMD processes. The measured data during the deposition tests have been used for comparing the efficiency of both powder and wire LMD processes. Afterwards, to evaluate the mechanical properties of the parts generated by means of both processes, standard tensile tests were carried out. Furthermore, other factors have been evaluated, such as process reliability or presence of residual material, after the deposition process. Findings Results show a higher efficiency of the wire LMD process, and even similar ultimate tensile stress values were reached for both processes; powder LMD parts resulted in a more brittle nature. Originality/value In the present paper, a thorough analysis that compared both processes has been carried out. The results obtained will help in the future when choosing between wire and powder LMD. The main points of the wealth of knowledge generated with these research efforts are highlighted herein.

Modeling and Experiments of Laser Cladding With Droplet Injection

2005 ◽  
Vol 127 (9) ◽  
pp. 978-986 ◽  
Author(s):  
J. Choi ◽  
L. Han ◽  
Y. Hua
Keyword(s):  
Fluid Flow ◽  
Laser Cladding ◽  
Dynamic Motion ◽  
Cladding Layer ◽  
Melt Pool ◽  
Material Deposition ◽  
Modeling And Experiments ◽  
Solid Liquid Interface ◽  
Solid Liquid ◽  
The Impact

Laser aided Directed Material Deposition (DMD) is an additive manufacturing process based on laser cladding. A full understanding of laser cladding is essential in order to achieve a steady state and robust DMD process. A two dimensional mathematical model of laser cladding with droplet injection was developed to understand the influence of fluid flow on the mixing, dilution depth, and deposition dimension, while incorporating melting, solidification, and evaporation phenomena. The fluid flow in the melt pool that is driven by thermal capillary convection and an energy balance at the liquid–vapor and the solid–liquid interface was investigated and the impact of the droplets on the melt pool shape and ripple was also studied. Dynamic motion, development of melt pool and the formation of cladding layer were simulated. The simulated results for average surface roughness were compared with the experimental data and showed a comparable trend.

Performance and Friction Properties of Injection Hybrid Moulds with Stereolithography Moulding Zones

2006 ◽  
Vol 514-516 ◽  
pp. 1673-1677 ◽  
Author(s):  
Mathias G. Westphal ◽  
António Sergio Pouzada ◽  
Gean V. Salmoria ◽  
Carlos H. Ahrens
Keyword(s):  
Structural Integrity ◽  
Chemical Properties ◽  
Rapid Manufacturing ◽  
Mechanical And Thermal Properties ◽  
Layer By Layer ◽  
Metallic Materials ◽  
Moulding Process ◽  
Photo Polymerization ◽  
Geometric Precision ◽  
And Chemical Properties

Stereolithography is a rapid manufacturing process that builds objects layer-by-layer based on the photo polymerization of a liquid resin. Due to the good geometric precision, this process has been used in Rapid Tooling for injection moulding. These tools are suitable for the production of short runs of parts and prototypes, where without resorting to the manufacture of a conventional metallic mould. The mechanical and thermal properties of the stereolitography resins, used in the manufacture of hybrid moulds, differ substantially from those of the conventional metallic materials. Particularly they must be known for guaranteeing the structural integrity and the thermal performance of the mould. Also the chemistry behaviour of the resin in contact with the polymer is important when tribological aspects are involved, especially during the ejection of the moulding. In this work, the behaviour of hybrid moulds with SL Vantico 5260 resin moulding cores was assessed. Several thermoplastics (iPP, ABS, PET and PA 6.6) were moulded, and their mechanical, thermal and chemical properties considered and related to the performance of the moulding process. Also, the friction properties of the SL resin in contact with the moulded thermoplastic in moulding conditions were observed and considered in the context of the performance of hybrid moulds.

Mechanically Stable Antireflection and Antifogging Coatings Fabricated by the Layer-by-Layer Deposition Process and Postcalcination

Langmuir ◽  
2008 ◽  
Vol 24 (19) ◽  
pp. 10851-10857 ◽  
Author(s):  
Lianbin Zhang ◽  
Yang Li ◽  
Junqi Sun ◽  
Jiacong Shen
Keyword(s):  
Deposition Process ◽  
Layer By Layer ◽  
Layer Deposition

Prediction of Melt-Pool Characteristics in SLM Process for Ti6Al4V Using a Semi-Analytical Model

2021 ◽  
Author(s):  
Shubhra Kamal Nandi ◽  
Rakesh Kumar ◽  
Anubhav ◽  
Anupam Agrawal
Keyword(s):  
Temperature Distribution ◽  
Finite Volume ◽  
Computational Models ◽  
Single Layer ◽  
Layer By Layer ◽  
Scanning Velocity ◽  
Melt Pool ◽  
Alternating Direction ◽  
Volume Method ◽  
Melt Pool Characteristics

Abstract Selective Laser Melting (SLM) is a powder-based layer-by-layer manufacturing technique to produce metallic customized shape components. The exceptionally high thermal gradient induces residual stress and distorts the part geometry affecting the yield quality. Computational models are instrumental in optimizing the process controls to fabricate high-quality components, and hence several such methods have been explored to simulate the thermal behavior of the process and the heat transfer in the melt-pool. Most of the practiced techniques are computationally expensive, making it infeasible to perform a parametric study. Based on closed-form exact heat conduction solution and Finite Volume Method (FVM), a pseudo-analytical thermal modeling approach has been employed to estimate the melt-pool characteristics and temperature distribution of the SLM process. A moving volumetric Gaussian heat source laser model and Green’s function have been adopted to model the heat input by conduction. The heat loss by conduction and convection has been calculated by implementing Finite Volume discretized equations on a 2-dimensional thin-walled domain with appropriate part boundary conditions. Additionally, the Alternating Direction Implicit iterative technique has been implemented for the fast convergence of the simulation. The model is used to demonstrate the influence of the process parameters and non-linear material phase change for a single-line single layer and multilayer part fabrication. The computed melt-pool dimensions and temperature distribution for varying laser-power, scanning velocity, and layer thickness for Ti6Al4V are validated with the experimental data from the literature with fair agreements.

Multiaxis wire and arc additive manufacturing for overhangs based on conical substrates

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Fusheng Dai ◽  
Shuaifeng Zhang ◽  
Runsheng Li ◽  
Haiou Zhang
Keyword(s):  
Principal Component Analysis ◽  
Additive Manufacturing ◽  
Design Methodology ◽  
Principal Component ◽  
Deposition Process ◽  
Content Type ◽  
Melt Pool ◽  
Planning Approach ◽  
Intelligent Approach ◽  
Supporting Structures

Purpose This paper aims to present a series of approaches for three-related issues in multiaxis in wire and arc additive manufacturing (WAAM) as follows: how to achieve a stable and robust deposition process and maintain uniform growth of the part; how to maintain consistent formation of a melt pool on the surface of the workpiece; and how to fabricate an overhanging structure without supports. Design/methodology/approach The principal component analysis-based path planning approach is proposed to compute the best scanning directions of slicing contours for the generation of filling paths, including zigzag paths and parallel skeleton paths. These printing paths have been experimented with in WAAM. To maintain consistent formation of a melt pool at overhanging regions, the authors introduce definitions for the overhanging point, overhanging distance and overhanging vector, with which the authors can compute and optimize the multiaxis motion. A novel fabricating strategy of depositing the overhanging segments as a support for the deposition of filling paths is presented. Findings The second principal component of a planar contour is a reasonable scanning direction to generate zigzag filling paths and parallel skeleton filling paths. The overhanging regions of a printing layer can be supported by pre-deposition of overhanging segments. Large overhangs can be successfully fabricated by the multiaxis WAAM process without supporting structures. Originality/value An intelligent approach of generating zigzag printing paths and parallel skeleton printing paths. Optimizations of depositing zigzag paths and parallel skeleton paths. Applications of overhanging point overhanging distance and overhanging vector for multiaxis motion planning. A novel fabricating strategy of depositing the overhanging segments as a support for the deposition of filling paths.

scholarly journals Refractometric Sensitivity Enhancement of Weakly Tilted Fiber Bragg Grating Integrated with Black Phosphorus

Nanomaterials ◽  
2020 ◽  
Vol 10 (7) ◽  
pp. 1423
Author(s):  
Zhao Zhang ◽  
Kun Liu ◽  
Junfeng Jiang ◽  
Tianhua Xu ◽  
Shuang Wang ◽  
...  
Keyword(s):  
Fiber Bragg Grating ◽  
Deposition Process ◽  
Sensitivity Enhancement ◽  
Black Phosphorus ◽  
Bragg Grating ◽  
Layer By Layer ◽  
Biochemical Sensing ◽  
Sensing Platform ◽  
Potential Applications ◽  
Cladding Mode

The sensitivity enhancement of the weakly tilted fiber Bragg grating (WTFBG) integrated with black phosphorus (BP) was investigated via numerical simulations and experimental demonstrations. BP nanosheets were deposited twice on the cylindrical WTFBG surface using the in situ layer-by-layer (i-LbL) deposition technique. The resonance intensity of the deepest cladding mode located around 1552 nm of WTFBG had a 9.2 dB decrease after the BP deposition process. This allows for the application of the intensity-modulated refractive index (RI) sensor. The sensing platform was implemented on the use of the BP integrated with WTFBG (BP-WTFBG). The refractometric sensing was achieved with the sensitivity enhancement of the resonance intensity modulation of the deepest cladding mode for the BP-WTFBG. The sensitivities were 137.6 dB/RIU and 75.6 dB/RIU in the RI region of 1.33–1.35 and 1.35–1.38, respectively. This platform shows great potential applications for biochemical sensing because of its highly sensitive RI sensing ability around the biochemical sensing window.

Sign in / Sign up

Export Citation Format

Share Document