Mechanical performance of plymetal structures subjected to impact loading

2017 ◽  
Vol 9 (1) ◽  
pp. 65-76
Author(s):  
SH Masood ◽  
D Ruan ◽  
P Rajapatruni
Keyword(s):  
Stainless Steel ◽  
Mechanical Performance ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Layer By Layer ◽  
Metal Powders ◽  
Metallic Structure ◽  
Stainless Steel 316L ◽  
Ballistic Performance ◽  
Ballistic Resistance

Plymetal is a new type of composite metallic structure based on the concept of plywood created by laser direct metal deposition additive manufacturing technology. Two different metal powders, 316L stainless steel and H13 tool steel, are deposited in alternative parallel rows in each layer in the defined orientations to create a plymetal structure. In this research, the plymetal was manufactured by the POM DMD 505 machine, in which a laser beam melts various metal powders deposited through a coaxial nozzle in a layer-by-layer manner to form a metallic structure. The ballistic performance of plymetal structures was then experimentally studied for high impact applications. Ballistic tests were carried out using a high-pressure gas gun. The plymetal plates of 3-mm-thick were subjected to impact of projectiles at various velocities and the results were compared with test results of stainless steel plates of different thicknesses. Results show that the ballistic resistance of the direct metal deposition generated plymetal structure is better than the ballistic resistance of the stainless steel 316L with the same thickness. Vickers hardness and face deformation characteristics of the plymetal samples and stainless steel samples were also investigated.

Development of Bio-Compatible Metallic Structures Using Direct Metal Deposition Process

2012 ◽  
Vol 576 ◽  
pp. 141-145
Author(s):  
Syed H. Riza ◽  
Syed H. Masood ◽  
Cui'e Wen ◽  
William Song
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Laser Power ◽  
Deposition Process ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Metal Powders ◽  
Micro Hardness ◽  
Metallic Structures ◽  
Ti6al4v Titanium Alloy

This paper investigates the capabilities of Direct Metal Deposition (DMD) process, which is a novel additive manufacturing technique, for creating structures that can be used as bone implants. Emphasis is on the use of bio-compatible metals, because metals are the most suitable materials in terms of mechanical strength when the requirement arises for supporting and replacing the load bearing bones and joints such as hip and knee. Specimens using two different metal powders, 41C stainless steel and Ti6Al4V titanium alloy, are generated by DMD process on mild steel and titanium plates as substrates respectively. Metallographic samples were made from the cladding, and tested for surface roughness and micro-hardness. The results indicate that at low laser power, hard and strong structures with good porosity can be successfully created using the DMD system.

Advances in Direct Metal Deposition

2013 ◽  
Author(s):  
Jyoti Mazumder ◽  
Lijun Song
Keyword(s):  
Additive Manufacturing ◽  
Optical Sensors ◽  
Thermal Cycle ◽  
Industrial Revolution ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Layer By Layer ◽  
Enabling Technology ◽  
Economic Space ◽  
Line Process

Recently Additive Manufacturing (AM) has been hailed as the “third industrial revolution” by The Economist magazine [April-2012]. Precision of the product manufactured by AM largely depends on the on line process diagnostics and control. AM caters to the quest for a material to suit the service performance, which is almost as old as the human civilization. An enabling technology which can build, repair or reconfigure components layer by layer or even pixel by pixel with appropriate materials to match the performance will enhance the productivity and thus reduce energy consumption. With the globalization, “Economic Space” for an organization is now spreads all across the globe. The promise of AM for Global Platform for precision additive manufacturing largely depends on the speed and accuracy of in-situ optical diagnostics and its capability to integrate with the process control. The two main groups of AM are powder bed (e.g. Laser Sintering) and pneumatically delivered powder (e.g. Direct Metal Deposition [DMD]) to fabricate components. DMD has closed loop capability, which enables better dimension and thermal cycle control. This enables one to deposit different material at different pixels with a given height directly from a CAD drawing. The feed back loop also controls the thermal cycle. New optical Sensors are either developed or being developed to control geometry using imaging, cooling rate by monitoring temperature, microstructure, temperature and composition using optical spectra. Ultimately these sensors will enable one to “Certify as you Build”. Flexibility of the process is enormous and essentially it is an enabling technology to materialize many a design. Several cases will be discussed to demonstrate the additional capabilities possible with the new sensors. Conceptually one can seat in Singapore and fabricate in Shanghai. Such systems will be a natural choice for a Global “Economic Space”.

Thermal Analysis and Verification for Direct Metal Deposition of 0Cr18Ni9 Stainless Steel

2019 ◽  
Author(s):  
Jin Wang ◽  
Jing Shi ◽  
Yi Wang ◽  
Yun Bai
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Temperature Distribution ◽  
Process Parameters ◽  
Thermal Stresses ◽  
Infrared Camera ◽  
Dimensional Accuracy ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Heating And Cooling

Abstract Due to rapid cyclic heating and cooling in metal additive manufacturing processes, such as selective laser melting (SLM) and direct metal deposition (DMD), large thermal stresses will form and this may lead to the loss of dimensional accuracy or even cracks. The integration of numerical analysis and experimental validation provides a powerful tool that allows the prediction of defects, and optimization of the component design and the additive manufacturing process parameters. In this work, a numerical simulation on the thermal process of DMD of 0Cr18Ni9 stainless steel is conducted. The simulation is based on the finite volume method (FVM). An in-house code is developed, and it is able to calculate the temperature distribution dynamically. The model size is 30mm × 30mm × 10.5mm, containing 432,000 cells. A DMD experiment on the material with the same configuration and process parameters is also carried out, during which an infrared camera is adopted to obtain the surface temperature distribution continuously, and thermocouples are embedded in the baseplate to record the temperature histories. It is found that the numerical results agree with the experimental results well.

Three-Dimensional Printing of Stainless Steel Parts

2008 ◽  
Vol 591-593 ◽  
pp. 374-379 ◽  
Author(s):  
Efrain Carreño-Morelli ◽  
Sebastien Martinerie ◽  
Lisa Mucks ◽  
B. Cardis
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Three Dimensional ◽  
Tensile Tests ◽  
Layer By Layer ◽  
Metal Powders ◽  
Selective Deposition ◽  
Three Dimensional Printing ◽  
Dimensional Printing ◽  
Metal Polymer

Stainless steel parts have been manufactured by two different layer by layer additive processes. The first one is a standard three dimensional process, in which metal powders are bound by selective deposition of binder with a printer head. The second one is a novel process, which is based on the selective deposition of a solvent on metal-polymer granule beds. The microstructures of green and sintered parts are characterized by optical and scanning electron microscopy, and the mechanical properties evaluated by hardness and tensile tests. Solvent on granule printing allows to reach mechanical properties similar to those of metal injection moulding parts.

Selective Laser Melting of Stainless Steel 316L for Mechanical Property-Gradation

2021 ◽  
Author(s):  
Yash Parikh ◽  
Mathew Kuttolamadom
Keyword(s):  
Stainless Steel ◽  
Selective Laser Melting ◽  
Mechanical Performance ◽  
Functionally Graded ◽  
Stainless Steel 316L ◽  
Laser Melting ◽  
Underlying Causes ◽  
Property Changes ◽  
Bulk Structures

Abstract With an end goal of creating single-alloy functionally-graded additively manufactured (FGAM) parts, this paper investigates the manufacture and properties of stainless steel 316L samples via a pulsed selective laser melting (SLM) process. The focus is on elucidating the underlying causes of property variations (within a functionally-acceptable range) through material characterization and testing. Five samples (made via different volumetric energy density-based process parameter sets) were down-selected from preliminary experimental results and analyzed for their microstructure, mechanical and physical properties (hardness, density/porosity, Young’s modulus). It was observed that property variations resulted from combinations of porosity types/amounts, martensitic phase fractions, and grain sizes. Based on these, various functionally-graded specimens of different sizes were built as per ASTM standards, each having intended property changes along its gauge volumes. The presented findings establish that a methodical control of microstructure and mechanical properties could be obtained in a repeatable and reproducible manner by changing the process parameters. This work lays the foundation for understanding and tuning the global mechanical performance of FGAM bulk structures as well as the role of interfacial zones.

Laser Cladding Based Solid Freeform Fabrication and Direct Metal Deposition

2006 ◽  
Author(s):  
Huan Qi ◽  
Jyotirmoy Mazumder
Keyword(s):  
Laser Beam ◽  
Laser Cladding ◽  
Solid Freeform Fabrication ◽  
Three Dimensional ◽  
High Energy ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Effective Control ◽  
Metal Powders ◽  
Freeform Fabrication

Three-dimensional additive manufacturing or solid freeform fabrication (SFF) techniques, originated in the rapid fabrication of non-functional physical prototypes in polymers (Rapid Prototyping), have matured to the manufacture of functional prototypes, short-run production products, and now even advanced engineering designs. Laser-based material deposition or laser cladding has been used as a SFF technique, in which a laser beam is used as a precise high-energy thermal source to melt preplaced or pneumatically delivered metal powders and make solidified deposits on a substrate. By using laser cladding techniques, three-dimensional fully dense components can be built line-by-line and layer-by-layer directly from a CAD model with tailored material properties. Laser cladding is essentially a fusion and solidification (thermal) process, which involves complicated interactions between the laser beam, metal powders, the base material (substrate), and processing gases. Maintaining a stable and uniform melt pool during laser cladding is critical to produce dimensional accuracy and material integrity. An effective control of energy (laser power) spatial and temporal distributions in either an open-loop or closed-loop laser cladding process is essential to achieve the high quality results. This paper reviews, from a laser-material interaction point of view, various laser cladding based SFF processes, and particularly the direct metal deposition technique.

Effects of electromagnetic field on the laser direct metal deposition of austenitic stainless steel

2019 ◽  
Vol 119 ◽  
pp. 105586 ◽  
Author(s):  
Yi Lu ◽  
Guifang Sun ◽  
Zhandong Wang ◽  
Yongkang Zhang ◽  
Boyong Su ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Electromagnetic Field ◽  
Austenitic Stainless Steel ◽  
Metal Deposition ◽  
Direct Metal Deposition

An Experimental Characterization of Powder/Substrate Interaction during Direct Metal Deposition for Additive Manufacturing

2019 ◽  
Vol 813 ◽  
pp. 435-440
Author(s):  
Maurizio Troiano ◽  
Alessia Teresa Silvestri ◽  
Fabio Scherillo ◽  
Andrea El Hassanin ◽  
Roberto Solimene ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Surface Morphology ◽  
Laser Power ◽  
Surface Characterization ◽  
Spot Size ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Metal Powders ◽  
Substrate Interaction

The physical behavior of metal powders during laser-based additive manufacturing processes has been investigated. In particular, an experimental campaign of direct metal deposition has been carried out to evaluate the effect of the laser power and spot size on the powder/substrate interaction and on the surface morphology of the final piece. A fast-camera has been used to evaluate the interaction phenomena during the printing process, while confocal microscopy has been carried out to measure the surface morphology of the samples. Results highlighted that increasing the laser power and laser spot size, the particle impact velocity is about constant, while the powder/laser/substrate interaction zone increases. As a consequence, the mean thickness increases, as confirmed by surface characterization.

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