Comparing the Sustainability Performance of Metal-Based Additive Manufacturing Processes

2017 ◽  
Author(s):  
Rothanak Chan ◽  
Sriram Manoharan ◽  
Karl R. Haapala
Keyword(s):  
Additive Manufacturing ◽  
Evaluation Method ◽  
Bottom Line ◽  
Powder Bed ◽  
Sustainability Performance ◽  
Quantitative Metrics ◽  
Direct Energy ◽  
Approach Method ◽  
Am Processes ◽  
Wire Feed

While there have been many advancements in additive manufacturing (AM) technologies for metal products, there has not been a great deal of attention paid toward developing an understanding of the relative sustainability performance of various AM processes for production of aerospace components, such as wire feed and powder bed fusion processes. This research presents a method to calculate and compare quantitative metrics for evaluating metal AM process on a basis of sustainability performance. The process-level evaluation method encompasses a triple bottom line analysis for low volume part production. A representative aerospace titanium alloy (Ti-6Al-4V) component is considered for the study and the production of the part is modeled using direct energy deposition (DED) as the representative wire feed AM process and selective laser melting (SLM) as the representative powder bed AM process. The results indicate that DED has a superior sustainability performance to SLM, mainly due to the relatively slower deposition rate and higher cost of material for SLM than DED. This research provides decision makers an approach method and a demonstrated case study in comparing DED and SLM AM processes. This understanding reveals advantages between the two options and offers avenues of future investigation for these technologies for further development and larger scale use.

The Environmental Impacts of Metal Powder Bed Additive Manufacturing

2020 ◽  
Vol 143 (3) ◽  
Author(s):  
Jiankan Liao ◽  
Daniel R. Cooper
Keyword(s):  
Additive Manufacturing ◽  
Environmental Impacts ◽  
Metal Powder ◽  
Future Research ◽  
Research Directions ◽  
Powder Bed ◽  
Direct Energy ◽  
Potential Benefits ◽  
Future Research Directions ◽  
Am Processes

Abstract Additive manufacturing (AM) is widely recognized as a critical pillar of advanced manufacturing and is moving from the design shop to the factory floor. As AM processes become more popular, it is paramount that engineers and policymakers understand and then reduce their environmental impacts. This article structures the current work on the environmental impacts of metal powder bed processes: selective laser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM), and binder jetting (BJ). We review the potential benefits and pitfalls of AM in each phase of a part's lifecycle and in different application domains (e.g., remanufacturing and hybrid manufacturing). We highlight critical uncertainties and future research directions throughout. The environmental impacts of AM are sensitive to the specific production and use-phase context; however, several broad lessons can be extracted from the literature. Unlike in conventional manufacturing, powder bed production impacts are dominated by the generation of the direct energy (electricity) required to operate the AM machines. Combined with a more energy-intensive feedstock (metal powder), this means that powder bed production impacts are higher than in conventional manufacturing unless production volumes are very small (saving tool production impacts), and/or there are significant material savings through part light weighting or improved buy-to-fly ratios.

The Environmental Impacts of Metal Powder Bed Additive Manufacturing

2020 ◽  
Author(s):  
Jiankan Liao ◽  
Daniel R. Cooper
Keyword(s):  
Additive Manufacturing ◽  
Environmental Impacts ◽  
Metal Powder ◽  
Future Research ◽  
Research Directions ◽  
Powder Bed ◽  
Direct Energy ◽  
Potential Benefits ◽  
Future Research Directions ◽  
Am Processes

Abstract Additive manufacturing (AM) is widely recognized as a critical pillar of advanced manufacturing and is moving from the design shop to the factory floor. As AM processes become more popular, it is paramount that engineers and policymakers understand and then reduce their environmental impacts. This article structures the current work on the environmental impacts of metal powder bed processes: selective laser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM), and binder jetting (BJ). We review the potential benefits and pitfalls of AM in each phase of a part’s lifecycle and in different application domains (e.g., remanufacturing, hybrid manufacturing etc.). We highlight critical uncertainties and future research directions throughout. The environmental impacts of AM are sensitive to the specific production and use-phase context; however, several broad lessons can be extracted from the literature. Unlike in conventional manufacturing, powder bed production impacts are dominated by the generation of the direct energy (electricity) required to operate the AM machines. Combined with a more energy-intensive feedstock (metal powder) this means that powder bed production impacts are higher than in conventional manufacturing unless production volumes are very small (saving tool production impacts) and/or there are significant material savings through part light weighting or improved buy-to-fly ratios.

Toward Metamodels for Composable and Reusable Additive Manufacturing Process Models

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Paul Witherell ◽  
Shaw Feng ◽  
Timothy W. Simpson ◽  
David B. Saint John ◽  
Pan Michaleris ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Metal Powder ◽  
Manufacturing Process ◽  
Process Model ◽  
Model Development ◽  
Process Models ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Future Work ◽  
Am Processes

In this paper, we advocate for a more harmonized approach to model development for additive manufacturing (AM) processes, through classification and metamodeling that will support AM process model composability, reusability, and integration. We review several types of AM process models and use the direct metal powder bed fusion AM process to provide illustrative examples of the proposed classification and metamodel approach. We describe how a coordinated approach can be used to extend modeling capabilities by promoting model composability. As part of future work, a framework is envisioned to realize a more coherent strategy for model development and deployment.

Anwendungszentrum für additive Fertigung/Center for Applied Additive Manufacturing – Influence of process parameters during high-speed laser direct energy deposition

2021 ◽  
Vol 111 (06) ◽  
pp. 368-371
Author(s):  
Sebastian Greco ◽  
Marc Schmidt ◽  
Benjamin Kirsch ◽  
Jan C. Aurich
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Energy Deposition ◽  
Influence Of Process Parameters ◽  
Direct Energy Deposition ◽  
Additive Fertigung ◽  
Powder Bed ◽  
High Productivity ◽  
Direct Energy ◽  
Near Net Shape

Additive Fertigungsverfahren zeichnen sich durch die Möglichkeit der endkonturnahen Fertigung komplexer Geometrien aus. Die geringe Produktivität etablierter Verfahren wie etwa dem Pulverbettverfahren hemmen aktuell den wirtschaftlichen Einsatz additiver Fertigung. Das Hochgeschwindigkeits-Laserauftragschweißen (HLA) soll durch deutlich erhöhte Auftragsraten und somit bisher unerreicht hoher Produktivität bei der additiven Fertigung dazu beitragen, deren Wirtschaftlichkeit zu steigern.   Additive manufacturing enables the near-net-shape production of complex geometries. The low productivity of established processes such as powder bed processes is currently limiting the economic use of additive manufacturing. High-speed laser direct energy deposition (HS LDED) is expected to improve the economic efficiency of additive manufacturing by significantly increasing deposition rates and thus previously unattained high productivity.

Additive Manufacturing of Nickel-Based Super Alloys for Aero Engine Applications

2020 ◽  
pp. 48-70
Author(s):  
Raja A. ◽  
Mythreyi O. V. ◽  
Jayaganthan R.
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Source Parameters ◽  
Raw Material ◽  
Layer By Layer ◽  
Powder Bed ◽  
Complex Design ◽  
Direct Energy ◽  
Second Phases ◽  
Metal Addition

Ni based super alloys are widely used in engine turbines because of their proven performance at high temperatures. Manufacturing these parts by additive manufacturing (AM) methods provides researchers a lot of creative space for complex design to improve efficiency. Powder bed fusion (PBF) and direct energy deposition (DED) are the two most widely-used metal AM methods. Both methods are influenced by the source, parameters, design, and raw material. Selective laser melting is one of the laser-based PBF techniques to create small layer thickness and complex geometry with greater accuracy and properties. The layer-by-layer metal addition generates epitaxial growth and solidification in the built direction. There are different second phases in the Ni-based superalloys. This chapter details the micro-segregation of these particles and its influence on the microstructure, and mechanical properties are dependent on the process influencing parameters, the thermal kinetics during the process, and the post-processing treatments.

scholarly journals An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3895 ◽  
Author(s):  
Abbas Razavykia ◽  
Eugenio Brusa ◽  
Cristiana Delprete ◽  
Reza Yavari
Keyword(s):  
Numerical Simulation ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Powder Bed Fusion ◽  
Laser Melting ◽  
Powder Bed ◽  
Part Quality ◽  
Melt Pool ◽  
Wide Range ◽  
Am Processes

Additive Manufacturing (AM) processes enable their deployment in broad applications from aerospace to art, design, and architecture. Part quality and performance are the main concerns during AM processes execution that the achievement of adequate characteristics can be guaranteed, considering a wide range of influencing factors, such as process parameters, material, environment, measurement, and operators training. Investigating the effects of not only the influential AM processes variables but also their interactions and coupled impacts are essential to process optimization which requires huge efforts to be made. Therefore, numerical simulation can be an effective tool that facilities the evaluation of the AM processes principles. Selective Laser Melting (SLM) is a widespread Powder Bed Fusion (PBF) AM process that due to its superior advantages, such as capability to print complex and highly customized components, which leads to an increasing attention paid by industries and academia. Temperature distribution and melt pool dynamics have paramount importance to be well simulated and correlated by part quality in terms of surface finish, induced residual stress and microstructure evolution during SLM. Summarizing numerical simulations of SLM in this survey is pointed out as one important research perspective as well as exploring the contribution of adopted approaches and practices. This review survey has been organized to give an overview of AM processes such as extrusion, photopolymerization, material jetting, laminated object manufacturing, and powder bed fusion. And in particular is targeted to discuss the conducted numerical simulation of SLM to illustrate a uniform picture of existing nonproprietary approaches to predict the heat transfer, melt pool behavior, microstructure and residual stresses analysis.

scholarly journals Hybrid additive manufacturing of steels and alloys

2020 ◽  
Vol 7 ◽  
pp. 6
Author(s):  
Vladimir V. Popov ◽  
Alexander Fleisher
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Modern Trend ◽  
Production Chain ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing

Hybrid additive manufacturing is a relatively modern trend in the integration of different additive manufacturing techniques in the traditional manufacturing production chain. Here the AM-technique is used for producing a part on another substrate part, that is manufactured by traditional manufacturing like casting or milling. Such beneficial combination of additive and traditional manufacturing helps to overcome well-known issues, like limited maximum build size, low production rate, insufficient accuracy, and surface roughness. The current paper is devoted to the classification of different approaches in the hybrid additive manufacturing of steel components. Additional discussion is related to the benefits of Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) approaches for hybrid additive manufacturing of steel components.

scholarly journals A functional modeling approach for quality assurance in metal additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Gijeong Seo ◽  
Md. RU Ahsan ◽  
Yousub Lee ◽  
Jong-Ho Shin ◽  
Hyungjun Park ◽  
...  
Keyword(s):  
Quality Assurance ◽  
Additive Manufacturing ◽  
Functional Design ◽  
Holistic View ◽  
Design Models ◽  
Content Type ◽  
Powder Bed ◽  
Critical Issues ◽  
New Research ◽  
Am Processes

Purpose Due to the complexity of and variations in additive manufacturing (AM) processes, there is a level of uncertainty that creates critical issues in quality assurance (QA), which must be addressed by time-consuming and cost-intensive tasks. This deteriorates the process repeatability, reliability and part reproducibility. So far, many AM efforts have been performed in an isolated and scattered way over several decades. In this paper, a systematically integrated holistic view is proposed to achieve QA for AM. Design/methodology/approach A systematically integrated view is presented to ensure the predefined part properties before/during/after the AM process. It consists of four stages, namely, QA plan, prospective validation, concurrent validation and retrospective validation. As a foundation for QA planning, a functional workflow and the required information flows are proposed by using functional design models: Icam DEFinition for Function Modeling. Findings The functional design model of the QA plan provides the systematically integrated view that can be the basis for inspection of AM processes for the repeatability and qualification of AM parts for reproducibility. Research limitations/implications A powder bed fusion process was used to validate the feasibility of this QA plan. Feasibility was demonstrated under many assumptions; real validation is not included in this study. Social implications This study provides an innovative and transformative methodology that can lead to greater productivity and improved quality of AM parts across industries. Furthermore, the QA guidelines and functional design models provide the foundation for the development of a QA architecture and management system. Originality/value This systematically integrated view and the corresponding QA plan can pose fundamental questions to the AM community and initiate new research efforts in the in-situ digital inspection of AM processes and parts.

scholarly journals Sensor-Based Additive Manufacturing Technologies

2021 ◽  
Vol 12 (3) ◽  
pp. 3513-3521
Keyword(s):  
Additive Manufacturing ◽  
Wearable Sensors ◽  
Sensor Technology ◽  
Layer By Layer ◽  
Environmental Sensors ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Building Components ◽  
Manufacturing Technologies

Additive manufacturing is the term that uses the CAD data to build components layer by layer; it is also termed layered manufacturing or 3D printing. The major advantage of additive manufacturing is the capability of building components without the use of molds or tools. Five major categories of AM processes include Powder Bed Fusion (PBF), Direct Energy Deposition (DED), Material Jetting (MJ), Binder Jetting (BJ), and Sheet Lamination (SL). The sensor may be defined as a device that responds to a physical stimulus and transmits a resulting impulse. Sensor technology has been widely adopted in advanced manufacturing, aerospace, biomedical and robotic applications. Commonly used sensors are temperature sensors, strain sensors, biosensors, environmental sensors, and wearable sensors, etc. Additive manufacturing technologies can fabricate sensors and microfluidic devices with less labor. This paper focuses on various sensors developed by additive manufacturing processes, and their practical application for the particular purpose is reviewed.

scholarly journals Hari metalikoetan eta arku elektrikoan oinarritutako fabrikazio-gehigarriko WAAM teknologiaren oinarriak eta aplikazioak

2021 ◽  
Author(s):  
Eider Aldalur ◽  
Asier Panfilo ◽  
Alfredo Súarez ◽  
Jone M. Ugartemendia
Keyword(s):  
Additive Manufacturing ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Powder Feed ◽  
Wire Arc Additive Manufacturing ◽  
Wire Feed

Fabrikazio-gehigarria geruzaz-geruza piezak eratzean oinarritzen den produkzio kontzeptu berria da. Fabrikazio-gehigarriaren barneko teknikek duten izaera dela eta, orain artean fabrikazio-teknika tradizionalek inposatutako diseinu mugak gainditzea ahalbidetzen dute. Material mota anitzetan lan egin dezaketen arren, lan honetan material metalikoetan oinarritutako fabrikazio-gehigarriko teknikak azalduko dira. Teknika hauek hiru multzo nagusitan sailka daitezke: Hauts-ohearen fusioa (Powder Bed Fusion, PBF), Hauts elikatzedun deposizioa (Powder Feed Systems, PFS) eta Hari elikatzedun deposizioa (Wire Feed Systems, WFS). Hauen artetik, WFS motaren barnean sailkatzen den arku eta hari bidezko fabrikazio gehigarrian (ingelesez, Wire Arc Additive Manufacturing (WAAM) bezala ezaguna) arreta berezia ezarriko da, erakusten dituen abantailak direla eta. Horien artean esanguratsuena, eskaintzen duen materialaren ezarpen-tasa altua da, tamaina handiko piezen fabrikazioa posible bihurtuz. Gainera, fabrikazio-teknika tradizionalekin alderatuz erabiltzen den material kantitatea murrizten du eta beraz, materialaren erabilera efizientzia altua lortzen da, amaierako piezatik gertu dauden aurreformak lortuz ondoren mekanizatu beharko direnak. Azkenik, WAAM teknologiaren bidez, soldagarria den edozein materialetan fabrika daitezke piezak, materiala hari metaliko formatuan sartzen delarik prozesuan. Hala, kilogramoko materialaren prezioa hari formatuan, zenbait fabrikazio-gehigarriko teknikak erabiltzen duten hauts formatuan baino askoz ere merkeagoa da. Gainera, lan honetan, zenbait aplikazio kasu ere azalduko dira aplikazio eremu bakoitzeko (fabrikazio zuzena, ez-zuzena eta konponketak) adibide bat azalduz.

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