scholarly journals Additive Manufacturing of H11 with Wire-Based Laser Metal Deposition

2017 ◽  
Vol 22 (4) ◽  
pp. 466-479 ◽  
Author(s):  
Stella Holzbach Oliari ◽  
Ana Sofia Clímaco Monteiro D’Oliveira ◽  
Martin Schulz
Keyword(s):  
Additive Manufacturing ◽  
Travel Speed ◽  
Metal Deposition ◽  
Parameters Optimization ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
3D Cad ◽  
Deposition Parameters ◽  
Commercial Applications ◽  
Functional Components

Abstract Laser additive manufacturing (LAM) is a near-net-shape production technique by which a part can be built up from 3D CAD model data, without material removal. Recently, these production processes gained attention due to the spreading of polymer-based processes in private and commercial applications. However, due to the insufficient development of metal producing processes regarding design, process information and qualification, resistance on producing functional components with this technology is still present. To overcome this restriction further studies have to be undertaken. The present research proposes a parametric study of additive manufacturing of hot work tool steel, H11. The selected LAM process is wire-based laser metal deposition (LMD-W). The study consists of parameters optimization for single beads (laser power, travel speed and wire feed rate) as well as lateral and vertical overlap for layer-by-layer technique involved in LMD process. Results show that selection of an ideal set of parameters affects substantially the surface quality, bead uniformity and bond between substrate and clad. Discussion includes the role of overlapping on the soundness of parts based on the height homogeneity of each layer, porosity and the presence of gaps. For the conditions tested it was shown that once the deposition parameters are selected, lateral and vertical overlapping determines the integrity and quality of parts processed by LAM.

Additive Manufacturing

2019 ◽  
pp. 165-183 ◽  
Author(s):  
Kamardeen Olajide Abdulrahman ◽  
Esther T. Akinlabi ◽  
Rasheedat M. Mahamood
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Titanium Aluminide ◽  
Three Dimensional ◽  
Physical And Mechanical Properties ◽  
Processing Parameters ◽  
Metal Deposition ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
Additive Process

Three-dimensional printing has evolved into an advanced laser additive manufacturing (AM) process with capacity of directly producing parts through CAD model. AM technology parts are fabricated through layer by layer build-up additive process. AM technology cuts down material wastage, reduces buy-to-fly ratio, fabricates complex parts, and repairs damaged old functional components. Titanium aluminide alloys fall under the group of intermetallic compounds known for high temperature applications and display of superior physical and mechanical properties, which made them most sort after in the aeronautic, energy, and automobile industries. Laser metal deposition is an AM process used in the repair and fabrication of solid components but sometimes associated with thermal induced stresses which sometimes led to cracks in deposited parts. This chapter looks at some AM processes with more emphasis on laser metal deposition technique, effect of LMD processing parameters, and preheating of substrate on the physical, microstructural, and mechanical properties of components produced through AM process.

scholarly journals Bead Geometry Prediction in Laser-Wire Additive Manufacturing Process Using Machine Learning: Case of Study

2021 ◽  
Vol 11 (24) ◽  
pp. 11949
Author(s):  
Natago Guilé Mbodj ◽  
Mohammad Abuabiah ◽  
Peter Plapper ◽  
Maxime El Kandaoui ◽  
Slah Yaacoubi
Keyword(s):  
Machine Learning ◽  
Additive Manufacturing ◽  
Prediction Model ◽  
Travel Speed ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Evolutionary Trend ◽  
Deposition Parameters ◽  
Layer Deposition ◽  
Height Prediction

In Laser Wire Additive Manufacturing (LWAM), the final geometry is produced using the layer-by-layer deposition (beads principle). To achieve good geometrical accuracy in the final product, proper implementation of the bead geometry is essential. For this reason, the paper focuses on this process and proposes a layer geometry (width and height) prediction model to improve deposition accuracy. More specifically, a machine learning regression algorithm is applied on several experimental data to predict the bead geometry across layers. Furthermore, a neural network-based approach was used to study the influence of different deposition parameters, namely laser power, wire-feed rate and travel speed on bead geometry. To validate the effectiveness of the proposed approach, a test split validation strategy was applied to train and validate the machine learning models. The results show a particular evolutionary trend and confirm that the process parameters have a direct influence on the bead geometry, and so, too, on the final part. Several deposition parameters have been found to obtain an accurate prediction model with low errors and good layer deposition. Finally, this study indicates that the machine learning approach can efficiently be used to predict the bead geometry and could help later in designing a proper controller in the LWAM process.

Laser additive manufacturing of copper– chromium–niobium alloys using gas atomized powder

2020 ◽  
Vol 111 (7) ◽  
pp. 587-593
Author(s):  
Dora Maischner ◽  
Udo Fritsching ◽  
Anoop Kini ◽  
Andreas Weisheit ◽  
Volker Uhlenwinkel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Rapid Solidification ◽  
Elevated Temperatures ◽  
High Strength ◽  
Copper Matrix ◽  
Metal Deposition ◽  
Raw Material ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
Niobium Alloys

Abstract Copper-chrome-niobium alloys exhibit excellent thermal and electrical properties combined with high strength at elevated temperatures. Additive manufacturing techniques such as laser metal deposition using powder as raw material offer the potential for rapid solidification as well as a high freedom of design to manufacture parts layer by layer. Powder samples of copper- chrome-niobium alloys were produced by gas atomization. Via laser metal deposition, bulk volumes without cracks and with a very low porosity can be built up. Rapid solidification leads to the formation of fine precipitates which are likely to be (Cr,Fe)2Nb. The precipitates are distributed homogeneously in the copper matrix. The copper crystals grow across the layers due to epitaxial nucleation on the preceding layer.

Tailor-Made Forging Tools by Laser Metal Deposition

2015 ◽  
Vol 651-653 ◽  
pp. 707-712 ◽  
Author(s):  
Daniel Junker ◽  
Oliver Hentschel ◽  
Michael Schmidt ◽  
Marion Merklein
Keyword(s):  
Additive Manufacturing ◽  
Mass Production ◽  
Metal Deposition ◽  
Cold Forging ◽  
Research Association ◽  
Laser Metal Deposition ◽  
High Carbon ◽  
Laser Additive Manufacturing ◽  
Laser Beam Melting ◽  
Functional Components

The desire for individualized products forces the companies to a great diversity of combinable parts. This way, the clients can compile their personalized product. As this trend is not just limited on visual parts but also for functional components, laser additive manufacturing of metals is used more and more often in manufacturing. To bring more additive manufacturing into mass production, Laser Beam Melting and Laser Metal Deposition will be qualified for the use in tool manufacturing within the Bavarian research association “ForNextGen – Next Generation Tools”. The first subproject within this research association investigates the potential of Laser Metal Deposition in the production of hot and cold forging tools. Within initial tests optimized process, parameters for the processing of the hot-work steel 1.2709 are determined by single welding beads. The achieved density and the inner structure are analyzed within cubes that were built with the investigated parameters. As forging tools are usually made of high-carbon tool steel, the processing of materials with a rising percentage of carbon will be part of further investigations.

A review of additive manufacturing applications in ophthalmology

2021 ◽  
pp. 095441192110280
Author(s):  
Arivazhagan Pugalendhi ◽  
Rajesh Ranganathan
Keyword(s):  
Additive Manufacturing ◽  
Treatment Planning ◽  
Physical Object ◽  
Layer By Layer ◽  
Case Examples ◽  
Manufacturing Method ◽  
3D Cad ◽  
Stl File ◽  
Potential Applications ◽  
Manufacturing Applications

Additive Manufacturing (AM) capabilities in terms of product customization, manufacture of complex shape, minimal time, and low volume production those are very well suited for medical implants and biological models. AM technology permits the fabrication of physical object based on the 3D CAD model through layer by layer manufacturing method. AM use Magnetic Resonance Image (MRI), Computed Tomography (CT), and 3D scanning images and these data are converted into surface tessellation language (STL) file for fabrication. The applications of AM in ophthalmology includes diagnosis and treatment planning, customized prosthesis, implants, surgical practice/simulation, pre-operative surgical planning, fabrication of assistive tools, surgical tools, and instruments. In this article, development of AM technology in ophthalmology and its potential applications is reviewed. The aim of this study is nurturing an awareness of the engineers and ophthalmologists to enhance the ophthalmic devices and instruments. Here some of the 3D printed case examples of functional prototype and concept prototypes are carried out to understand the capabilities of this technology. This research paper explores the possibility of AM technology that can be successfully executed in the ophthalmology field for developing innovative products. This novel technique is used toward improving the quality of treatment and surgical skills by customization and pre-operative treatment planning which are more promising factors.

The role of robotics in additive manufacturing: review of the AM processes and introduction of an intelligent system

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
J. Norberto Pires ◽  
Amin S. Azar ◽  
Filipe Nogueira ◽  
Carlos Ye Zhu ◽  
Ricardo Branco ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Intelligent System ◽  
Material Selection ◽  
High Strength Steels ◽  
Industrial Applications ◽  
Layer By Layer ◽  
Content Type ◽  
Functional Components

Purpose Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology. Design/methodology/approach AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices. Findings The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically. Research limitations/implications This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors. Originality/value The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.

scholarly journals Surface Hardness as a Function of Laser Metal Deposition Parameters

2015 ◽  
Vol 24 (4) ◽  
pp. 272-279 ◽  
Author(s):  
WH Kim ◽  
BH Jung ◽  
ID Park ◽  
MH Oh ◽  
SW Choi ◽  
...  
Keyword(s):  
Surface Hardness ◽  
Metal Deposition ◽  
Laser Metal Deposition ◽  
Deposition Parameters

scholarly journals Build-up strategies for additive manufacturing of three dimensional Ti-6Al-4V-parts produced by laser metal deposition

2018 ◽  
Vol 30 (2) ◽  
pp. 022001 ◽  
Author(s):  
Felix Spranger ◽  
Benjamin Graf ◽  
Michael Schuch ◽  
Kai Hilgenberg ◽  
Michael Rethmeier
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Metal Deposition ◽  
Laser Metal Deposition

Additive Manufacturing for Crack Repair Applications in Metals

2019 ◽  
pp. 77-101
Author(s):  
Tawanda Marazani ◽  
Daniel Makundwaneyi Madyira ◽  
Esther Titilayo Akinlabi
Keyword(s):  
Additive Manufacturing ◽  
Crack Detection ◽  
Metal Deposition ◽  
Maintenance And Repair ◽  
Freeform Fabrication ◽  
3D Cad ◽  
Repair Technique ◽  
Ti Alloys ◽  
Crack Repair ◽  
Am Applications

Additive manufacturing (AM) builds intricate parts from 3D CAD model data in successive layers. AM offers several advantages and has become a preferred freeform fabrication, processing, manufacturing, maintenance, and repair technique for metals, thermoplastics, ceramics, and composites. When using laser, it bears several names, which include laser additive manufacturing, laser additive technology, laser metal deposition, laser engineered net shape, direct metal deposition, and laser solid forming. These technologies use a laser beam to locally melt the powder or wire and the substrate that fuse upon solidification. AM is mainly applied in the aerospace and biomedical industries. Titanium (Ti) alloys offer very attractive properties much needed in these industries. This chapter explores AM applications for crack repairs in Ti alloys. Metal cracking industrial challenges, crack detection and repair methods, challenges, and milestones for AM repair of cracks in Ti alloys are also discussed.

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