scholarly journals Investigation of High-Depostition-Rate Additive Manufacturing of Ti-6Al-4V via Laser Material Deposition

2021 ◽  
Author(s):  
Rebar Hama-Saleh ◽  
Kerim Yildirim ◽  
Susanne Hemes ◽  
Andreas Weisheit ◽  
Constantin Leon Häfner
Keyword(s):  
Additive Manufacturing ◽  
Hot Forging ◽  
Scanning Speed ◽  
Inert Atmosphere ◽  
High Deposition Rate ◽  
Beam Diameter ◽  
Deposition Rates ◽  
Laser Material ◽  
Aerospace Applications ◽  
Material Deposition

Ti-6Al-4V is the most prominent titanium alloy widely used e.g. for aerospace applications. Conventionally, many Ti-6Al-4V aerospace components are produced by a multi-stage hot forging process followed by subsequent machining which often generates a high amount of scrap. Additive manufacturing (AM), such as powder-based laser material deposition (p-LMD), enables parts to be made with geometric freedom and near-net-shape, but so far lacks high deposition rates. The present study proposes high-deposition-rate laser material deposition manufacturing using a large laser beam diameter and increased scanning speed to achieve deposition rates up to 5 kg/h. As Ti-6Al-4V is prone to oxygen pick-up, the process was performed in an inert atmosphere. We determined suitable process windows for tracks without fusion defects and low porosity and investigated microstructure and hardness.

Study of process window development for high deposition-rate laser material deposition by using mixed processing parameters

2015 ◽  
Vol 27 (3) ◽  
pp. 032008 ◽  
Author(s):  
Chongliang Zhong ◽  
Andres Gasser ◽  
Jochen Kittel ◽  
Thomas Schopphoven ◽  
Norbert Pirch ◽  
...  
Keyword(s):  
Deposition Rate ◽  
Processing Parameters ◽  
Process Window ◽  
High Deposition Rate ◽  
Laser Material ◽  
Material Deposition

Experimental study of porosity reduction in high deposition-rate Laser Material Deposition

2015 ◽  
Vol 75 ◽  
pp. 87-92 ◽  
Author(s):  
Chongliang Zhong ◽  
Andres Gasser ◽  
Thomas Schopphoven ◽  
Reinhart Poprawe
Keyword(s):  
Experimental Study ◽  
Deposition Rate ◽  
High Deposition Rate ◽  
Laser Material ◽  
Porosity Reduction ◽  
Material Deposition

Development of a high-speed laser material deposition process for additive manufacturing

2021 ◽  
Vol 33 (1) ◽  
pp. 012021
Author(s):  
Jonathan Schaible ◽  
Lennart Sayk ◽  
Thomas Schopphoven ◽  
Johannes Henrich Schleifenbaum ◽  
Constantin Häfner
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Deposition Process ◽  
Laser Material ◽  
Material Deposition

Investigation of mechanical properties and microstructures of GH536 fabricated by laser powder bed fusion additive manufacturing

2020 ◽  
Vol 235 (1-2) ◽  
pp. 155-165
Author(s):  
Yunpeng Ren ◽  
Heng Lu ◽  
Dongyang Xu ◽  
Yan Chen ◽  
Zhiduo Xin ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Additive Manufacturing ◽  
Relative Density ◽  
Laser Energy ◽  
Hot Forging ◽  
Scanning Speed ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed

Laser powder bed fusion additive manufacturing of superalloys has received increasing attention in these years. In this article, the influence of parameters of laser powder bed fusion on mechanical properties and microstructures of nickel-based superalloy GH536 was investigated. Influence of laser power, scanning speed, hatch space and building direction on mechanical properties was discussed, and the optimal parameters were obtained. The relative density of samples fabricated by laser powder bed fusion could be as high as 99.5%. The processing window of laser energy density with 8.56 × 104–1.15 × 105 J/cm3 should be employed to make sure that the relative density is higher than 98%. The ultimate tensile strength and yield stress of GH536 sample made by laser powder bed fusion were 950 and 606 MPa, respectively, which were superior to samples with the tensile strength of 767 MPa and yield strength of 379 MPa prepared by traditional hot forging method. The hardness of the sample could reach 316.8 HV.

Particle velocity measurement in powder gas jets of coaxial powder nozzles for laser material deposition

2021 ◽  
Vol 33 (1) ◽  
pp. 012019
Author(s):  
Jonathan Schaible ◽  
Luis Andrea Hau ◽  
David Weber ◽  
Thomas Schopphoven ◽  
Constantin Häfner ◽  
...  
Keyword(s):  
Particle Velocity ◽  
Velocity Measurement ◽  
Laser Material ◽  
Gas Jets ◽  
Material Deposition ◽  
Particle Velocity Measurement

Using Statistical Methods to Optimize Patterning Parameters for Tungsten Deposition

2007 ◽  
Author(s):  
Michael DiBattista ◽  
Kimball Skinner ◽  
Rick Kneedler ◽  
Leonid Vasilvey ◽  
Lukas Drybcak ◽  
...  
Keyword(s):  
Failure Analysis ◽  
Statistical Methods ◽  
Deposition Rates ◽  
Low Resistivity ◽  
Material Deposition ◽  
Deposition Parameters ◽  
Beam Parameters

Abstract Circuit edit and failure analysis require tungsten deposition parameters to accomplish different goals. Circuit edit applications desire low resistivity values for rewiring, while failure analysis requires high deposition rates for capping layers. Tungsten deposition can be a well controlled process for a variety of beam parameters. For circuit edit, tungsten resistivity approaching below 150 µohm-cm and 50 μm3/nC is predicted. Material deposition rates of 80 μm3/nC can be achieved with reasonable pattern accuracy using defocus as a parameter.

Control of humping phenomenon and analyzing mechanical properties of Al–Si wire-arc additive manufacturing fabricated samples using cold metal transfer process

2021 ◽  
pp. 095440622199840
Author(s):  
Yashwant Koli ◽  
N Yuvaraj ◽  
Aravindan Sivanandam ◽  
Vipin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Heat Input ◽  
Large Scale ◽  
High Deposition Rate ◽  
Bead Geometry ◽  
Layer By Layer ◽  
Cold Metal Transfer ◽  
Geometrical Shapes ◽  
Wire Arc Additive Manufacturing

Nowadays, rapid prototyping is an emerging trend that is followed by industries and auto sector on a large scale which produces intricate geometrical shapes for industrial applications. The wire arc additive manufacturing (WAAM) technique produces large scale industrial products which having intricate geometrical shapes, which is fabricated by layer by layer metal deposition. In this paper, the CMT technique is used to fabricate single-walled WAAM samples. CMT has a high deposition rate, lower thermal heat input and high cladding efficiency characteristics. Humping is a common defect encountered in the WAAM method which not only deteriorates the bead geometry/weld aesthetics but also limits the positional capability in the process. Humping defect also plays a vital role in the reduction of hardness and tensile strength of the fabricated WAAM sample. The humping defect can be controlled by using low heat input parameters which ultimately improves the mechanical properties of WAAM samples. Two types of path planning directions namely uni-directional and bi-directional are adopted in this paper. Results show that the optimum WAAM sample can be achieved by adopting a bi-directional strategy and operating with lower heat input process parameters. This avoids both material wastage and humping defect of the fabricated samples.

Fabrication of circular cooling channels by cold metal transfer based wire and arc additive manufacturing

2021 ◽  
pp. 095440542199561
Author(s):  
Shaohua Han ◽  
Zhongzhong Zhang ◽  
Pengxiang Ruan ◽  
Shiwen Cheng ◽  
Dingqi Xue
Keyword(s):  
Additive Manufacturing ◽  
High Energy ◽  
Cooling Effect ◽  
High Deposition Rate ◽  
Cooling Channel ◽  
Conformal Cooling Channel ◽  
Conformal Cooling ◽  
Energy Beam ◽  
Cooling Channels ◽  
Straight Line

Additive manufacturing has been proven to be a promising technology for fabricating high-performance dies, molds, and conformal cooling channels. As one of the manufacturing methods, wire and arc additive manufacturing displays unique advantages of low cost and high deposition rate that are better than other high energy beam-based ones. This paper presents a preliminary study of fabricating integrated cooling channels by CMT-based wire and arc additive manufacturing process. The deposition strategies for fabricating circular cross-sectional cooling channels both in conformal and straight-line patterns have been investigated. It included optimizing the welding torch angle, fabricating the enclosed semicircle structure and predicting the collision between the torch and constructed part. The cooling effect test was also conducted on both the conformal cooling channel and straight-line cooling channel. The results affirmed a higher cooling efficiency and better uniform cooling effect of the conformal cooling channel than straight-line cooling channel.

A Literature Review on the Wire and Arc Additive Manufacturing—Welding Systems and Software

2021 ◽  
Vol 13 (8) ◽  
pp. 1391-1400
Author(s):  
Zidong Lin ◽  
Pengfei Liu ◽  
Xinghua Yu
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Tool Path ◽  
Future Research ◽  
High Deposition Rate ◽  
Efficient Technology ◽  
The Past ◽  
Material Efficiency ◽  
Systems Software ◽  
Design Generation

Wire and arc additive manufacturing (WAAM) is considered to be an economic and efficient technology that is suitable to produce large-scale and ultra-large-scale metallic components. In the past two decades, it has been widely investigated in different fields, such as aerospace, automotive and marine industries. Due to its relatively high deposition rate, material efficiency, and shortened lead time compared to other powder-based additive manufacturing (AM) techniques, wire and arc additive manufacturing (WAAM) has been significantly noticed and adopted by both academic researchers and industrial engineers. In order to summarize the development achievements of wire and arc additive manufacturing (WAAM) in the past few years and outlook the development direction in the coming days, this paper provides an overview of 3D metallic printing by applying it as a deposition method. The review mainly focuses on the current welding systems, software for tool path design, generation, and planning used in wire and arc additive manufacturing (WAAM). In the end, the state of the art and future research on wire and arc additive manufacturing (WAAM) have been prospected.

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