scholarly journals Engineering and Economic Aspects of Additive Manufacturing in Energy Related Industries

2020 ◽  
Author(s):  
Sandip Dutta ◽  
Sagar Dasgupta ◽  
Geetha Chimata
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Production Methods ◽  
Energy Applications ◽  
Recent Developments ◽  
Subtractive Manufacturing ◽  
Manufacturing Methods ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing ◽  
Am Processes

Additive manufacturing is the buzz word these days and many companies are leaning on this technology to leap forward in un-chartered design space that promises to give better performance at impossible to reach design goals with the current manufacturing methods. This paper addresses recent developments that have occurred in Energy related businesses with the adoption of 3D printing, also known as Additive Manufacturing (AM). It covers what and why of additive manufacturing; what constitutes energy and AM industry; current activities in AM for energy; AM for different energy sectors; AM processes; AM applications; selected patents in additive manufacturing associated with energy applications; and economic and financial aspects of AM in energy related industries. In this review paper it was noted that in-spite of phenomenal growth in AM, it seldom replaces traditional production methods due to associated constraints. Many companies are finding complimentary AM processes along with subtractive manufacturing techniques to meet the market demands. However, AM is particularly advantageous and attractive compared to traditional manufacturing methods for low volume complex geometry parts.

scholarly journals The Corrosion of Stainless Steel Made by Additive Manufacturing: A Review

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 516
Author(s):  
Gyeongbin Ko ◽  
Wooseok Kim ◽  
Kyungjung Kwon ◽  
Tae-Kyu Lee
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Relevant Literature ◽  
Corrosion Property ◽  
Corrosion Study ◽  
Direct Laser ◽  
Manufacturing Methods ◽  
Traditional Manufacturing ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

The advantages of additive manufacturing (AM) of metals over traditional manufacturing methods have triggered many relevant studies comparing the mechanical properties, corrosion behavior, and microstructure of metals produced by AM or traditional manufacturing methods. This review focuses exclusively on the corrosion property of AM-fabricated stainless steel by comprehensively analyzing the relevant literature. The principles of various AM processes, which have been adopted in the corrosion study of stainless steel, and the corrosion behaviors of stainless steel depending on the AM process, the stainless steel type, and the corrosion environment are summarized. In this comprehensive analysis of relevant literature, we extract dominant experimental factors and the most relevant properties affecting the corrosion of AM-fabricated stainless steel. In selective laser melting, the effects of the scan speed, laser power, energy density, and the post-treatment technologies are usually investigated. In direct laser deposition, the most relevant papers focused on the effect of heat treatments on passive films and the Cr content. There has been no specific trend in the corrosion study of stainless steel that is fabricated by other AM processes, such as wire arc additive manufacturing. Given the rising utilization of AM-produced metal parts, the corrosion issue will be more important in the future, and this review should provide a worthwhile basis for future works.

Recent Developments of the Multiphysics Discrete Element Method for Additive Manufacturing Modeling and Simulation

2017 ◽  
Author(s):  
John C. Steuben ◽  
Athanasios P. Iliopoulos ◽  
John G. Michopoulos
Keyword(s):  
Additive Manufacturing ◽  
Discrete Element Method ◽  
Discrete Element ◽  
Additive Manufacture ◽  
Computational Tools ◽  
Computational Performance ◽  
Macro Scale ◽  
Recent Developments ◽  
Am Processes ◽  
Element Method

Recent years have seen a sharp increase in the development and usage of Additive Manufacturing (AM) technologies for a broad range of scientific and industrial purposes. The drastic microstructural differences between materials produced via AM and conventional methods has motivated the development of computational tools that model and simulate AM processes in order to facilitate their control for the purpose of optimizing the desired outcomes. This paper discusses recent advances in the continuing development of the Multiphysics Discrete Element Method (MDEM) for the simulation of AM processes. This particle-based method elegantly encapsulates the relevant physics of powder-based AM processes. In particular, the enrichment of the underlying constitutive behaviors to include thermoplasticity is discussed, as are methodologies for modeling the melting and re-solidification of the feedstock materials. Algorithmic improvements that increase computational performance are also discussed. The MDEM is demonstrated to enable the simulation of the additive manufacture of macro-scale components. Concluding remarks are given on the tasks required for the future development of the MDEM, and the topic of experimental validation is also discussed.

Additive Manufacturing: The Next Generation of Scapholunate Ligament Reconstruction

2021 ◽  
Author(s):  
Matthew N. Rush ◽  
Christina Salas ◽  
Lorraine Mottishaw ◽  
Damian Fountain ◽  
Deana Mercer
Keyword(s):  
Additive Manufacturing ◽  
Ligament Reconstruction ◽  
Three Dimensional ◽  
Biological Properties ◽  
Bone Interface ◽  
Significant Strength ◽  
Efficient Integration ◽  
Manufacturing Methods ◽  
Manufacturing Techniques ◽  
Manufacturing Technologies

Abstract Background Ligament reconstruction, as a surgical method used to stabilize joints, requires significant strength and tissue anchoring to restore function. Historically, reconstructive materials have been fraught with problems from an inability to withstand normal physiological loads to difficulties in fabricating the complex organization structure of native tissue at the ligament-to-bone interface. In combination, these factors have prevented the successful realization of nonautograft reconstruction. Methods A review of recent improvements in additive manufacturing techniques and biomaterials highlight possible options for ligament replacement. Description of Technique In combination, three dimensional-printing and electrospinning have begun to provide for nonautograft options that can meet the physiological load and architectures of native tissues; however, a combination of manufacturing methods is needed to allow for bone-ligament enthesis. Hybrid biofabrication of bone-ligament tissue scaffolds, through the simultaneous deposition of disparate materials, offer significant advantages over fused manufacturing methods which lack efficient integration between bone and ligament materials. Results In this review, we discuss the important chemical and biological properties of ligament enthesis and describe recent advancements in additive manufacturing to meet mechanical and biological requirements for a successful bone–ligament–bone interface. Conclusions With continued advancement of additive manufacturing technologies and improved biomaterial properties, tissue engineered bone-ligament scaffolds may soon enter the clinical realm.

scholarly journals Investigation of microstructure and hardness of a rib geometry produced by metal forming and wire-arc additive manufacturing

2018 ◽  
Vol 190 ◽  
pp. 02005 ◽  
Author(s):  
Markus Hirtler ◽  
Angelika Jedynak ◽  
Benjamin Sydow ◽  
Alexander Sviridov ◽  
Markus Bambach
Keyword(s):  
Additive Manufacturing ◽  
Metal Forming ◽  
Batch Size ◽  
Unit Costs ◽  
Batch Sizes ◽  
Traditional Manufacturing ◽  
Manufacturing Technologies ◽  
Forming Tools ◽  
Wire Arc Additive Manufacturing ◽  
Am Processes

Within the scope of consumer-oriented production, individuality and cost-effectiveness are two essential aspects, which can barely be met by traditional manufacturing technologies. Conventional metal forming techniques are suitable for large batch sizes. If variants or individualized components have to be formed, the unit costs rise due to the inevitable tooling costs. For such applications, additive manufacturing (AM) processes, which do not require tooling, are more suitable. Due to the low production rates and limited build space of AM machines, the manufacturing costs are highly dependent on part size and batch size. Hence, a combination of both manufacturing technologies i.e. conventional metal forming and additive manufacturing seems expedient for a number of applications. The current study develops a process chain combining forming and additive manufacturing. First, a semi-finished product is formed with forming tools of reduced complexity and then finished by additive manufacturing. This research investigates the addition of features using AlSi12 created by Wire Arc Additive Manufacturing (WAAM) on formed EN-AW 6082 preforms. By forming, the strength of the material was increased, while this effect was partly reduced by the heat input of the WAAM process.

Computational Study of Reinforcement Mechanisms of Cuttlefish Bone Inspired Structure for 3D Printing

2021 ◽  
Author(s):  
Brandon Bethers ◽  
Yang Yang
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Computational Study ◽  
High Energy ◽  
Simulation Software ◽  
Support Structures ◽  
Common Support ◽  
Potential Applications ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing

Abstract Cuttlebone, the internal shell structure of a cuttlefish, presents a unique labyrinthian wall-septa design that promotes high energy absorption, porosity, and damage tolerance. This structure offers us an inspiration for the design of lightweight and strong structures for potential applications in mechanical, aerospace and biomedical engineering. However, the complexity of the cuttlebones structural design makes its fabrication by traditional manufacturing techniques not feasible. The advances in additive manufacturing (3D printing) make highly complex structures like cuttlebone possible to manufacture. In this work, the authors sought to establish comparative data between cuttlebone structures and some common support structures used in additive manufacturing. The structures compared to cuttlebone in this work include the cubic, honeycomb and triangular support structures. This was accomplished by using CAD modeling and simulation software. This study found that the cuttlefish structures had higher average stress values than the others but similar average strain values. This leads to a higher modulus of elasticity for the cuttlebone structures. The data suggests that further research into cuttlebone structures could produce future designs that improve upon the current well-established additive manufacturing support structures. Further study will be performed for the 3D printing of cuttlebone inspired structures by using various types of materials, such as soft and rigid polymers, functional ceramics, composites, and metals.

scholarly journals Hybrid additive manufacturing of steels and alloys

2020 ◽  
Vol 7 ◽  
pp. 6
Author(s):  
Vladimir V. Popov ◽  
Alexander Fleisher
Keyword(s):  
Additive Manufacturing ◽  
Energy Deposition ◽  
Modern Trend ◽  
Production Chain ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Manufacturing Techniques ◽  
Traditional Manufacturing

Hybrid additive manufacturing is a relatively modern trend in the integration of different additive manufacturing techniques in the traditional manufacturing production chain. Here the AM-technique is used for producing a part on another substrate part, that is manufactured by traditional manufacturing like casting or milling. Such beneficial combination of additive and traditional manufacturing helps to overcome well-known issues, like limited maximum build size, low production rate, insufficient accuracy, and surface roughness. The current paper is devoted to the classification of different approaches in the hybrid additive manufacturing of steel components. Additional discussion is related to the benefits of Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) approaches for hybrid additive manufacturing of steel components.

scholarly journals Design of Additively Manufactured Structures for Biomedical Applications: A Review of the Additive Manufacturing Processes Applied to the Biomedical Sector

2019 ◽  
Vol 2019 ◽  
pp. 1-6 ◽  
Author(s):  
Flaviana Calignano ◽  
Manuela Galati ◽  
Luca Iuliano ◽  
Paolo Minetola
Keyword(s):  
Additive Manufacturing ◽  
Biomedical Applications ◽  
Point Of View ◽  
Disruptive Technology ◽  
Manufacturing Processes ◽  
Medical Field ◽  
Successful Case ◽  
Design Perspective ◽  
Manufacturing Techniques ◽  
Am Processes

Additive manufacturing (AM) is a disruptive technology as it pushes the frontier of manufacturing towards a new design perspective, such as the ability to shape geometries that cannot be formed with any other traditional technique. AM has today shown successful applications in several fields such as the biomedical sector in which it provides a relatively fast and effective way to solve even complex medical cases. From this point of view, the purpose of this paper is to illustrate AM technologies currently used in the medical field and their benefits along with contemporary. The review highlights differences in processes, materials, and design of additive manufacturing techniques used in biomedical applications. Successful case studies are presented to emphasise the potentiality of AM processes. The presented review supports improvements in materials and design for future researches in biomedical surgeries using instruments and implants made by AM.

Incorporating Manufacturing Constraints in Topology Optimization Methods: A Survey

2017 ◽  
Author(s):  
Alok Sutradhar ◽  
Jaejong Park ◽  
Payam Haghighi ◽  
Jacob Kresslein ◽  
Duane Detwiler ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Methods ◽  
Manufacturing Processes ◽  
Complex Geometries ◽  
Manufacturing Constraints ◽  
Post Processing ◽  
Optimization Framework ◽  
Manufacturing Methods ◽  
Traditional Manufacturing

Topology optimization provides optimized solutions with complex geometries which are often not suitable for direct manufacturing without further steps or post-processing by the designer. There has been a recent progression towards linking topology optimization with additive manufacturing, which is less restrictive than traditional manufacturing methods, but the technology is still in its infancy being costly, time-consuming, and energy inefficient. For applications in automotive or aerospace industries, the traditional manufacturing processes are still preferred and utilized to a far greater extent. Adding manufacturing constraints within the topology optimization framework eliminates the additional design steps of interpreting the topology optimization result and converting it to viable manufacturable parts. Furthermore, unintended but inevitable deviations that occur during manual conversion from the topology optimized result can be avoided. In this paper, we review recent advances to integrate (traditional) manufacturing constraints in the topology optimization process. The focus is on the methods that can create manufacturable and well-defined geometries. The survey will discuss the advantages, limitations, and related challenges of manufacturability in topology optimization.

scholarly journals Analysis and characterization of additive manufacturing processes

2021 ◽  
Vol 13 (4) ◽  
pp. 167-180
Author(s):  
Andra TOFAN-NEGRU ◽  
Cristian BARBU ◽  
Amado STEFAN ◽  
Ioana-Carmen BOGLIS
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Cutting Tools ◽  
Manufacturing Processes ◽  
Layer By Layer ◽  
Advantages And Disadvantages ◽  
Finishing Processes ◽  
Short Time ◽  
Physical Phenomena ◽  
Am Processes

Recently, additive manufacturing (AM) processes have expanded rapidly in various fields of the industry because they offer design freedom, involve layer-by-layer construction from a computerized 3D model (minimizing material consumption), and allow the manufacture of parts with complex geometry (thus offering the possibility of producing custom parts). Also, they provide the advantage of a short time to make the final parts, do not involve the need for auxiliary resources (cutting tools, lighting fixtures or coolants) and have a low impact on the environment. However, the aspects that make these technologies not yet widely used in industry are poor surface quality of parts, uncertainty about the mechanical properties of products and low productivity. Research on the physical phenomena associated with additive manufacturing processes is necessary for proper control of the phenomena of melting, solidification, vaporization and heat transfer. This paper addresses the relevant additive manufacturing processes and their applications and analyzes the advantages and disadvantages of AM processes compared to conventional production processes. For the aerospace industry, these technologies offer possibilities for manufacturing lighter structures to reduce weight, but improvements in precision must be sought to eliminate the need for finishing processes.

scholarly journals Comparative Studies on Additive and Subtractive Manufacturing in Nigeria Case Study: Helical Gear in a Juice Extractor

2019 ◽  
pp. 1-11
Author(s):  
C. F. Nwaeche ◽  
A. O. Fagunwa ◽  
A. A. Olokoshe ◽  
A. E. Aderowmu ◽  
V. C. T. Uzondu ◽  
...  
Keyword(s):  
Manufacturing Industries ◽  
Helical Gears ◽  
Manufacturing Method ◽  
Advantages And Disadvantages ◽  
Additive Method ◽  
Subtractive Manufacturing ◽  
Manufacturing Methods ◽  
Manufacturing Techniques ◽  
Additive Methods

All over the world, additive and subtractive manufacturing are the two basic manufacturing methods used for the development of engineering goods and products. In most cases, the method adopted by the manufacturers usually depends on its cost-effectiveness. However, most of the manufacturing industries in Nigeria have little or no information on the relative advantages and disadvantages of the two methods. This had led to many industries adopting one particular method hook, line and sinker without considering the merits that would be offered by the alternative manufacturing method. This paper, therefore, compared the two methods of manufacturing by carrying out reverse engineering of worn-out helical gears (components of a juice extractor) developed using additive and subtractive manufacturing techniques. The parts of the equipment were developed using a lathe, milling and deburring machines to carry out the drilling, turning, grinding, milling and deburring for subtractive manufacturing and 3-D printing machine for additive method. Two gears A and B were developed by both subtractive and additive methods using the dimension of two old gears, which serve as the basis for determining the variation of the nomenclatures of the developed gears from the standard. The time used for product development, cost of production and the energy expended during the production of the two gears using additive and subtractive manufacturing methods were also determined using appropriate methods. The study also showed that it is less expensive to produce both gears A and B using the additive method than the subtractive method. Similarly, in term of energy used, less energy was used during fabrication of the gears using additive method than subtractive method but in general, when you want to print a whole component at once the 3D printer volume could be a major constraint. Hence, the adaptation of additive manufacturing method as a whole or part with the existing subtractive method will help to improve manufacturing industries in Nigeria.

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