scholarly journals PRODUCTION OF PROTOTYPE PARTS USING DIRECT METAL LASER SINTERING TECHNOLOGY

2015 ◽  
Vol 55 (4) ◽  
pp. 260 ◽  
Author(s):  
Josef Sedlak ◽  
Oskar Zemčík ◽  
Martin Slaný ◽  
Josef Chladil ◽  
Karel Kouřil ◽  
...  
Keyword(s):  
Rapid Prototyping ◽  
Automotive Industry ◽  
Laser Sintering ◽  
Additive Technologies ◽  
Metal Powders ◽  
Direct Metal Laser Sintering ◽  
Direct Production ◽  
Unconventional Methods ◽  
Material Preparation ◽  
Economic Comparison

<p>Unconventional methods of modern materials preparation include additive technologies which involve the sintering of powders of different chemical composition, granularity, physical, chemical and other utility properties. The technology called Rapid Prototyping, which uses different technological principles of producing components, belongs to this type of material preparation. The Rapid Prototyping technology facilities use photopolymers, thermoplastics, specially treated paper or metal powders. The advantage is the direct production of metal parts from input data and the fact that there is no need for the production of special tools (moulds, press tools, etc.). Unused powder from sintering technologies is re-used for production 98% of the time, which means that the process is economical, as well as ecological.The present paper discusses the technology of Direct Metal Laser Sintering (DMLS), which falls into the group of additive technologies of Rapid Prototyping (RP). The major objective is a detailed description of DMLS, pointing out the benefits it offers and its application in practice. The practical part describes the production and provides an economic comparison of several prototype parts that were designed for testing in the automotive industry.</p>

The effect of different build orientations on the consolidation, tensile and fracture toughness properties of direct metal laser sintering Ti-6Al-4V

2018 ◽  
Vol 24 (2) ◽  
pp. 276-284 ◽  
Author(s):  
Hamza Hassn Alsalla ◽  
Christopher Smith ◽  
Liang Hao
Keyword(s):  
Mechanical Properties ◽  
Fracture Toughness ◽  
Laser Sintering ◽  
Full Density ◽  
Full Detail ◽  
Original Research ◽  
Metal Powders ◽  
Direct Metal Laser Sintering ◽  
Cast Material ◽  
Content Type

Purpose The purpose of this paper is to study new process parameters which were selected to achieve the full density of Ti-6Al-4V samples in different building orientations and investigate fracture toughness property and its relation to the microstructure, an area which has not previously been reported in full detail and which may offer information to a designer. Direct metal laser sintering (DMLS) is an additive manufacturing technique that directly manufactures three-dimensional parts, layer-by-layer, to scan and melt metal powders for aerospace applications. Design/methodology/approach Hardness and tensile tests were carried out to evaluate the effect of consolidation on the mechanical performance of specimens made at three different building directions. Optical and electron microscopy were used to characterise the microstructure of the DMLS specimens and their effects on the fractures and mechanical properties. Findings It was found that the built samples have an excellent density at 4.5 g/cm, and the sample surfaces parallel to the building direction are rougher than the perpendicular surfaces. The fracture toughness result was higher than that of the cast material for the same alloy and higher than the Ti-6Al-4V parts fabricated by electron beam melting. This results in the superior mechanical properties of DMLS, while slightly lower in the zy direction owing to cracks, porosity and surface finish. Research limitations/implications The tensile strength was found to be higher than the wrought material, and the samples exhibited brittle fractures owing to the martensitic phase, which is caused by a high temperature gradient, and the mechanical properties change with the change in the microstructures at different building directions. Originality/value This paper contains original research.

Influence of the Direct Metal Laser Sintering Process on the Fatigue Behavior of the Ti6Al4V Alloy

2017 ◽  
Vol 891 ◽  
pp. 317-321 ◽  
Author(s):  
Adrián Bača ◽  
Radomila Konečná ◽  
Gianni Nicoletto
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Fatigue Behavior ◽  
Laser Sintering ◽  
Ti6al4v Alloy ◽  
Process Conditions ◽  
Layer By Layer ◽  
Metal Powders ◽  
Direct Metal Laser Sintering ◽  
Post Process

Direct Metal Laser Sintering (DMLS) is additive manufacturing (AM) process that can produce near net shape parts from metal powders such as titanium alloys. DMLS is a layer by layer additive manufacturing technique based on high power fiber laser that creates solid layers from loose powder material and joins them in an additive manner. The specific DMLS process conditions, lead to a specific and complex microstructure and to mechanical properties that show a degree of directionality. It was found that microstructural characteristics are related to the building process parameters. The aim of this work is to evaluate the fatigue performance of the Ti6Al4V alloy depending on the process parameters, building orientations and post-process heat treatment.

scholarly journals МЕТОД СОЗДАНИЯ МОДЕЛЕЙ САМОЛЕТОВ С ПОМОЩЬЮ СИСТЕМ CAD/CAM/CAE И АДДИТИВНЫХ ТЕХНОЛОГИЙ

2018 ◽  
pp. 24-34
Author(s):  
Ю. Б. Витязев ◽  
А. Г. Гребеников ◽  
А. М. Гуменный ◽  
А. М. Ивасенко ◽  
А. А. Соболев
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Selective Laser Sintering ◽  
Laser Sintering ◽  
Additive Technologies ◽  
Direct Metal Laser Sintering ◽  
Fused Deposition ◽  
Cad Cam ◽  
Deposition Modeling ◽  
Laser Stereolithography

The analysis of the most applicable in mechanical engineering additive technologies (fused deposition modeling, selective laser sintering, laser stereolithography, direct metal laser sintering) have been performed. Method of creating airplane models using CAD/CAM/CAE systems and additive manufacturing is presented. The results of the application of selective laser sintering and fused deposition modeling for the manufacture of training aircraft models are considered.

A Thermal Strength State Analysis of a Cylindrical Combustion Chamber Manufactured Using Additive Technologies

2020 ◽  
pp. 68-79
Author(s):  
E.S. Ushakova ◽  
K.Yu. Arefyev ◽  
S.V. Zaikin ◽  
A.R. Polyanskiy ◽  
V.V. Isakov
Keyword(s):  
Combustion Chamber ◽  
Power Plants ◽  
Laser Sintering ◽  
Additive Technologies ◽  
Strength Characteristics ◽  
Material Strength ◽  
Layer By Layer ◽  
Metal Powders ◽  
Operating Modes ◽  
Direct Laser

Additive technologies based on layer-by-layer and direct laser sintering of metal powders make it possible to produce objects of complex shapes with high accuracy and at acceptable material and time costs. However, the implementation of additive technologies is associated with a number of technical difficulties caused by a decrease in strength characteristics of the material obtained as a result of laser sintering. The negative trend associated with deterioration of the material strength characteristics and its influence on the structure performance is most pronounced in heat-stressed units, in particular, in combustion chambers of power plants. The paper proposes and tests a computational and experimental method for estimating the stress-strain state of a regenerative cooled cylindrical combustion chamber manufactured using additive technologies. The authors present experimental data on the decrease in the material strength when laser sintering of power is used. The change in the safety factor of the cylindrical combustion chamber is estimated depending on its geometric characteristics and operating modes. The possibility of application of the developed method when choosing the configuration of a combustion chamber with regenerative cooling channels is shown.

Direct Metal Laser Sintering – New Possibilities in Biomedical Part Manufacturing

2007 ◽  
Vol 534-536 ◽  
pp. 461-464 ◽  
Author(s):  
Juha Kotila ◽  
Tatu Syvänen ◽  
Jouni Hänninen ◽  
Maria Latikka ◽  
Olli Nyrhilä
Keyword(s):  
Biomedical Applications ◽  
Laser Sintering ◽  
Direct Metal Laser Sintering ◽  
Cobalt Chromium ◽  
Direct Production ◽  
Molybdenum Alloys ◽  
Surgical Devices ◽  
Rapid Production ◽  
Metallic Parts ◽  
Cobalt Chromium Molybdenum

Direct Metal Laser Sintering (DMLS) has been utilized for prototype manufacturing of functional metal components for years now. During this period the surface quality, mechanical properties, detail resolution and easiness of the process have been improved to the level suitable for direct production of complex metallic components for various applications. The paper will present the latest DMLS technology utilizing EOSINT M270 laser sintering machine and EOSTYLE support generation software for direct and rapid production of complex shaped metallic components for various purposes. The focus of the presentation will be in rapid manufacturing of customized biomedical implants and surgical devices of the latest stainless steel, titanium and cobalt-chromium-molybdenum alloys. In addition to biomedical applications, other application areas where complex metallic parts with stringent requirements are being needed will be presented.

Density Gradient Materials by Direct Metal Laser Sintering

2010 ◽  
Vol 89-91 ◽  
pp. 281-284 ◽  
Author(s):  
Hyun Goo Kang ◽  
Toshiko Osada ◽  
Hideshi Miura
Keyword(s):  
Porous Structure ◽  
Density Gradient ◽  
Laser Power ◽  
Laser Sintering ◽  
Metal Powders ◽  
Direct Metal Laser Sintering ◽  
Stainless Steel 316L ◽  
Size Change ◽  
Cross Sectional ◽  
Gradient Materials

The direct metal laser sintering process was applied to produce density gradient materials of stainless steel 316L. In order to understand the mechanism of forming porous structure, the influence of laser power, scan rate and scan pitch on the porosity were investigated by measuring density of produced samples and observing cross-sectional microstructures. Laser power greatly affected to the porosity by forming clusters of melted metal powders. It was found that the size change of clusters plays a role in forming porous structure. Eventually, three dimensional sample owing density gradient structures was manufactured.

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