scholarly journals On the Features of Composite Coating, Based on Nickel Alloy and Aluminum–Iron Bronze, Processed by Direct Metal Deposition

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 957
Author(s):  
Eugene E. Feldshtein ◽  
Oleg Devojno ◽  
Marharyta Kardapolava ◽  
Nikolaj Lutsko ◽  
Justyna Patalas-Maliszewska
Keyword(s):  
Additive Manufacturing ◽  
Composite Coating ◽  
Ceramic Materials ◽  
Metal Substrate ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Metal Alloys ◽  
Aluminum Iron ◽  
Manufacturing Technologies ◽  
Intensive Development

In recent years, additive manufacturing technologies have become increasingly widespread with the most intensive development being direct metal deposition (DMD), alloys, and ceramic materials on a metal substrate. This study shows the possibilities of the effective formation of coatings, based on heterogeneous metal alloys (Ni-based alloy and Fe-Al bronze) deposited onto 1045 structural steel. Changes in the microhardness, the microstructure, and the tribological properties of the composite coating, depending on the laser spot speed and pitch during DMD processing, have been considered. It was revealed that if the components of the composite coating are chosen correctly, there are possible DMD conditions ensuring reliable and durable connection between them and with the substrate.

scholarly journals Metastable Al–Si–Ni Alloys for Additive Manufacturing: Structural Stability and Energy Release during Heating

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 483 ◽  
Author(s):  
Tibor Bedo ◽  
Bela Varga ◽  
Daniel Cristea ◽  
Alexandra Nitoi ◽  
Andrea Gatto ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Melt Spinning ◽  
Practical Importance ◽  
Metal Alloys ◽  
Heating Process ◽  
Structural Development ◽  
Ni Alloys ◽  
Metastable Structures ◽  
High Cooling Rates ◽  
Manufacturing Technologies

Rapid solidification with high cooling rates of metal alloys determines both the improvement of mechanical properties, due to the finishing of the structure, as well as obtaining metastable structures in the form of supersaturated or amorphous/nano solid solutions, which could potentially confer the material outstanding properties. It is of particular interest to use the energies released during the heating stage for these materials, due to the potentially lower input energy required to melt/fuse these materials. This phenomenon could add to the development and diversification of additive manufacturing technologies. The paper presents results concerning the structural development and phase transformation of metastable structures from Al–Si–Ni-based alloys, obtained by melt spinning and atomization techniques. It was observed that the structural transformations occurring during the heating process, starting from metastable structures, generate significant amounts of energy. This is of practical importance in the use of metallic powders in additive manufacturing technology, due to potentially reduced energy input.

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.

scholarly journals A Study of the Structural Characteristics of Titanium Alloy Products Manufactured Using Additive Technologies by Combining the Selective Laser Melting and Direct Metal Deposition Methods

Materials ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3269 ◽  
Author(s):  
Marina Samodurova ◽  
Ivan Logachev ◽  
Nataliya Shaburova ◽  
Olga Samoilova ◽  
Liudmila Radionova ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
Selective Laser Melting ◽  
Structural Characteristics ◽  
Metal Deposition ◽  
Additive Technologies ◽  
Direct Metal Deposition ◽  
Geometrical Shape ◽  
Laser Melting ◽  
Manufacturing Technologies

Titanium alloy product manufacturing is traditionally considered to be a rather difficult task. Additive manufacturing technologies, which have recently become quite widespread, can ensure the manufacture of titanium alloys products of an arbitrary geometrical shape. During this study, we have developed a methodology for manufacturing titanium alloys products using additive technologies on FL-Clad-R-4 complex of laser melting of metals by combined Selective Laser Melting (SLM) and Direct Metal Deposition (DMD) methods. Ti–6Al–4V and Ti–6Al–4Mo–1V alloys were used for the manufacture of samples. We studied the microstructure of the obtained details and measured the microhardness of the samples. We discovered a gradient of the structure throughout the height of the details walls, which is connected with the peculiarities of thermal cycles of the technology used. This affected the microhardness values: in the upper part of the details, the microhardness is 10–25% higher (about 500 HV) than in the lower part (about 400 HV). Products made according to the developed technique do not have visible defects and pores. The obtained results indicate the competitiveness of the proposed methodology.

Precision additive manufacturing of NiTi parts using micro direct metal deposition

2018 ◽  
Vol 96 (9-12) ◽  
pp. 3729-3736 ◽  
Author(s):  
Saeed Khademzadeh ◽  
Filippo Zanini ◽  
Paolo F. Bariani ◽  
Simone Carmignato
Keyword(s):  
Additive Manufacturing ◽  
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.

Fast Computation of Thermal Field of Direct Metal Deposition: A Preliminary Study Based on Quiet Element Method

2018 ◽  
Author(s):  
Jin Wang ◽  
Jing Shi ◽  
Yi Wang ◽  
Yuli Hu ◽  
Jun Dai ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Thermal Field ◽  
High Energy ◽  
Metal Deposition ◽  
Direct Metal Deposition ◽  
Convergence Criterion ◽  
Fast Computation ◽  
Commercial Software ◽  
Element Analysis ◽  
Element Method

Direct metal deposition (DMD) is a major additive manufacturing (AM) process, which employs high energy beams as the heat source to melt and deposit metals in layerwise fashion so that complex structural components can be directly obtained. Similar to other metal AM processes, DMD is a complicated thermo-mechanical process, characterized by fast scan rates, large thermal gradients, rapid material phase transformations, and cyclic non-uniform temperature changes. Accurate and efficient computation of the thermal field during the DMD process is essential for understanding the fundamental microstructure evolution and developing the optimization strategy. In this paper, we aim to develop an open-source and fast computation tool for analyzing the heat transfer during the DMD process, which is based on the finite volume formulation and the quiet element method and allows development of customized functionalities at the source level. A computing tool is developed in MATLAB for fast prediction of the temperature field during metal additive manufacturing, and compared against the regular finite element analysis using a commercial software. The preliminary results show that for a system of 14400 cells, deposition of a single path takes 174 s using the commercial software, and 15.8s to 81s depending on the setting of convergence criterion using the in-house code. This represents a time reduction ranged from 90.9% to 53.4%, and the overall error is around 12.1%.

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