Material Efficiency and Economics of Hybrid Additive Manufacturing

2021 ◽  
Author(s):  
Peter Francis Reginald Elvis ◽  
Senthilkumaran Kumaraguru
Keyword(s):  
Additive Manufacturing ◽  
Case Studies ◽  
Cost Effective ◽  
Machining Process ◽  
Total Production ◽  
Material Efficiency ◽  
Aerospace Applications ◽  
Feature Based ◽  
Near Net Shaping ◽  
Net Shaping

Abstract In the past few years, Hybrid Additive Manufacturing has emerged to take advantage of both Additive Manufacturing and Subtractive Manufacturing processes and also to overcome the limitation of one process with the other. In aerospace applications, material wastage has become an issue in conventional machining process which reflects in total production cost and time. Especially, when dealing with expensive materials, conventional processes lack material efficiency with high buy-to-fly ratio which results in increased material cost. This paper deals with Hybrid Additive Manufacturing involving two different volume partitioning strategies — (i) Feature-based volume partitioning method (ii) Stock-based near net-shaping volume partitioning method to discuss the economics and material efficiency of Hybrid Additive Manufacturing process via simple cost estimator (formulated from the existing literature) by comparing these two volume partitioning strategies through suitable case studies — (i) Turbine blade and (ii) Impeller. From the results, it was found that the feature-based volume partitioning method was found to be material efficient and cost effective than the stock based near net shaping volume partitioning method in both the case studies.

Laser Deposition-Additive Manufacturing of Graphene Oxide Reinforced IN718 Alloys: Effects on Surface Quality, Microstructure, and Mechanical Properties

2019 ◽  
Author(s):  
Yingbin Hu ◽  
Hui Wang ◽  
Weilong Cong
Keyword(s):  
Wear Resistance ◽  
Graphene Oxide ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Metal Matrix ◽  
Selective Laser Sintering ◽  
Laser Deposition ◽  
Shaping Process ◽  
Near Net Shaping ◽  
Net Shaping

Abstract Owing to its high stiffness and strength, low density, and excellent flexibility, nano-sized graphene oxide (GO) is considered as a competitive material to reinforce metallic materials. Conventional manufacturing methods for GO reinforced metal matrix fabrication include casting and powder metallurgy, both of which demonstrate disadvantages of high reinforcement agglomeration, high cost, and difficulty in fabrication of complex structures. To reduce these problems, it is important to investigate a finely-controlled, cost-saving, and near-net-shaping process for GO reinforced metal matrix manufacturing. Laser additive manufacturing is such a process that mainly includes selective laser sintering / melting (SLS / M) and laser deposition-additive manufacturing (LD-AM). Compared with SLS / M, LD-AM demonstrates parts remanufacturing capability and is capable of fabricating functionally gradient materials. In this investigation, GO reinforced Inconel 718 (IN718) parts, for the first time, are fabricated using LD-AM processes. The effects of GO on flatness, surface roughness, microstructure, microhardness, and wear resistance of LD-AM fabricated GO reinforced IN718 parts are studied. Experimental results show that the introduction of GO is beneficial for enhancing both microhardness and wear resistance but harmful to surface quality of fabricated parts. In addition, the presence of GO has little influence on microstructures.

Laser-Based Manufacturing Processes for Aerospace Applications

2017 ◽  
pp. 374-391
Author(s):  
Panos Stavropoulos ◽  
Angelos Koutsomichalis ◽  
Nikos Vaxevanidis
Keyword(s):  
Aerospace Industry ◽  
Cost Effective ◽  
Machining Process ◽  
Machining Processes ◽  
Aerospace Applications ◽  
Advanced Manufacturing Technologies ◽  
Laser Manufacturing ◽  
The Difference ◽  
Manufacturing Technologies ◽  
Wear Tool

In this chapter the latest developments in Laser manufacturing technologies and processes, used in the aerospace industry, are discussed. Current developments in the aerospace industry are characterised by the reduction of manufacturing and exploitation costs. Thus, the need for implementation of advanced manufacturing technologies and processes in the aeronautic industry, offering cost effective products with improved life cycle, is becoming more and more imperative. Lasers can be used in many industrial machining processes for a variety of materials including metals, ceramics, glass, plastics, and composites. Laser beams, used as machining tools, are not accompanied by problems such as tool wear, tool breakage, chatter, machine deflection and mechanically induced material damage, phenomena that are usually associated with traditional machining processes. The effectiveness of Lasers depends on the thermal nature of the machining process. Nevertheless, difficulties arise due to the difference in the thermal properties of the various components.

An Investigation of Process Parameters on Selective Laser Melting of Nitinol

2013 ◽  
Author(s):  
Jason Walker ◽  
Mohammad Elahinia ◽  
Christoph Haberland
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Material Behavior ◽  
Laser Melting ◽  
Direct Fabrication ◽  
Shape Memory Effects ◽  
Near Net Shaping ◽  
Net Shaping ◽  
Actuation Systems

Nitinol’s superelastic and shape memory effects can be used in passive or active actuation systems. Often used in the aerospace industry, the use of Nitinol for actuation is also growing in the biomedical fields and elsewhere. However, the industry currently lacks the ability to produce complex Nitinol actuators, which is strictly limiting its potential. The extreme difficulty of machining Nitinol complicates manufacturing processes. Furthermore, the transformation temperatures which drive Nitinol’s unique behavior are extremely sensitive to the relative concentrations of nickel and titanium. Therefore, exceptionally tight compositional control during production is necessary to guarantee ideal material behavior. Additive manufacturing (AM) is a near-net-shaping technology which allows for the direct fabrication of complex metallic components. In this way, the (lack of) machinability of Nitinol is no longer an issue because no traditional machining is required during fabrication. Using AM also enables production of 3D geometries that are not possible using traditional techniques. Features such as engineered porosity, hollow parts, curved holes and filigree structures are suddenly realizable. Furthermore, direct CAD fabrication reduces the timescale of the concept-to-prototype transition. A major breakthrough in additive manufacturing came with the development of fiber laser technology in the mid-1990’s, which enables direct melting of manufacturing grade metals into fully dense parts. This technology became known as selective laser melting (SLM). Despite its huge potential, SLM of Nitinol has received little attention from the engineering world. In the present work, two different SLM machines (Realzier SLM 100 and Phenix Systems PXM) are used to develop Nitinol components directly from powder. Adjustment and optimization of the process parameters on the product are analyzed and compared.

Classification and Automatic Feature-Based Extraction Approach for Cylindrical and Milling Parts

2021 ◽  
Vol 11 (3) ◽  
pp. 55-73
Author(s):  
Sathish Kumar Adapa ◽  
Dowluru Sreeramulu ◽  
Jagadish
Keyword(s):  
Case Studies ◽  
Process Planning ◽  
Feature Recognition ◽  
Recognition Algorithm ◽  
Machining Process ◽  
Automatic Extraction ◽  
Java Program ◽  
Feature Based ◽  
Logical Rules ◽  
Conventional Machining

This paper reports classification and automatic extraction of various cylindrical and milling features in conventional machining process parts. In this work, various algorithms like hole recognition algorithm (HRA) and milling feature recognition algorithm (MFRA) have been used for identification of different cylindrical and milling features. A cylindrical feature is identified based on specific logical rules, and milling feature is identified based on the concept of concave decomposition of edges. In-house developed JAVA program is used to write algorithm, and then validation of the algorithm is done through two case studies. The HRA and MFRA algorithms extract the cylindrical features (through holes, blind holes, taper holes, and bosses) and milling features (slot, blind slot, step, blind step, pockets) precisely. The current work is well suitable to extract the features in conventional machining parts and thereby improve the downstream applications likes process planning, CAPP, CAM, etc.

Additive Manufacturing of Nitinol Shape Memory Alloys to Overcome Challenges in Conventional Nitinol Fabrication

2014 ◽  
Author(s):  
Jason Walker ◽  
Mohsen Taheri Andani ◽  
Christoph Haberland ◽  
Mohammad Elahinia
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory ◽  
Thermal Characteristics ◽  
Material Behavior ◽  
Direct Fabrication ◽  
Shape Memory Effects ◽  
Near Net Shaping ◽  
Net Shaping ◽  
Actuation Systems ◽  
Compositional Control

The pseudoelastic and shape memory effects of NiTi can be used in passive or active actuation systems. Often used in the aerospace industry, the use of NiTi for actuation is also growing in the biomedical fields and elsewhere. However, it’s potential in industry is currently limited by the inability to produce complex NiTi parts. Conventional manufacturing processes are complicated by the extreme difficulty associated with machining NiTi. Furthermore, the transformation temperatures which drive the unique behavior of NiTi as a shape memory alloy are extremely sensitive to the relative concentrations of nickel and titanium. Therefore, exceptionally tight compositional control during production is necessary to guarantee ideal material behavior. Additive manufacturing (AM) is a near-net-shaping technology which allows for the direct fabrication of complex metallic components. By utilizing the AM processing principle, the poor machinability of NiTi is no longer an issue. Using AM also enables production of 3D geometries that are not possible using traditional techniques. Furthermore, direct CAD fabrication reduces the timescale of the concept-to-prototype transition. In the present work, an SLM machine (Phenix Systems PXM) is used to develop NiTi components directly from powder. The thermal characteristics and shape memory functionality of SLM NiTi components is demonstrated.

Additive Manufacturing of Shape Memory Devices and Pseudoelastic Components

2013 ◽  
Author(s):  
Christoph Haberland ◽  
Mohammad Elahinia ◽  
Jason Walker ◽  
Horst Meier ◽  
Jan Frenzel
Keyword(s):  
Additive Manufacturing ◽  
Shape Memory ◽  
Raw Material ◽  
Processing Route ◽  
High Quality ◽  
Manufacturing Method ◽  
Structural And Functional Properties ◽  
Shape Memory Effects ◽  
Near Net Shaping ◽  
Net Shaping

Processing of Nickel-Titanium shape memory alloys (NiTi) is by no means easy because all processing steps can strongly affect the properties of the material. Hence, near-net-shaping technologies are very attractive for processing NiTi due to reduction of the processing route. Additive Manufacturing (AM) provides especially promising alternatives to conventional processing because it offers unparalleled freedom of design. In the last 5 years AM of NiTi received little attention from academics and researchers and, therefore, is far from being established for processing NiTi today. This work is to highlight the current state of the art of using the AM technique Selective Laser Melting (SLM) for processing high quality NiTi parts. For this reason, fundamentals for SLM processing of NiTi are described. It is shown in detail that a careful control of process parameters is of great importance. Furthermore, this work characterizes structural and functional properties like shape recovery, referring to the shape memory effect in Ti-rich SLM NiTi, or pseudoelasticy in Ni-rich SLM NiTi. It is shown that both types of shape memory effects can be adjusted in SLM NiTi by the choice of the raw material and processing strategy. By comparing the properties of SLM NiTi to those of conventionally processed NiTi, this work clearly shows that SLM is an attractive manufacturing method for production of high quality NiTi parts.

Laser-Based Manufacturing Processes for Aerospace Applications

2016 ◽  
pp. 24-45
Author(s):  
Panos Stavropoulos ◽  
Angelos Koutsomichalis ◽  
Nikos Vaxevanidis
Keyword(s):  
Aerospace Industry ◽  
Cost Effective ◽  
Machining Process ◽  
Machining Processes ◽  
Aerospace Applications ◽  
Advanced Manufacturing Technologies ◽  
Laser Manufacturing ◽  
The Difference ◽  
Manufacturing Technologies ◽  
Wear Tool

In this chapter the latest developments in Laser manufacturing technologies and processes, used in the aerospace industry, are discussed. Current developments in the aerospace industry are characterised by the reduction of manufacturing and exploitation costs. Thus, the need for implementation of advanced manufacturing technologies and processes in the aeronautic industry, offering cost effective products with improved life cycle, is becoming more and more imperative. Lasers can be used in many industrial machining processes for a variety of materials including metals, ceramics, glass, plastics, and composites. Laser beams, used as machining tools, are not accompanied by problems such as tool wear, tool breakage, chatter, machine deflection and mechanically induced material damage, phenomena that are usually associated with traditional machining processes. The effectiveness of Lasers depends on the thermal nature of the machining process. Nevertheless, difficulties arise due to the difference in the thermal properties of the various components.

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