scholarly journals Near Net Shape Manufacture of Titanium Alloy Components from Powder and Wire: A Review of State-of-the-Art Process Routes

Metals ◽  
2019 ◽  
Vol 9 (6) ◽  
pp. 689 ◽  
Author(s):  
Thomas Childerhouse ◽  
Martin Jackson
Keyword(s):  
Titanium Alloy ◽  
Medical Implants ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Post Process ◽  
Material Usage ◽  
Direct Energy ◽  
Near Net Shape ◽  
Am Processes ◽  
Metal Additive

Near net shape (NNS) manufacturing offers an alternative to conventional processes for the manufacture of titanium alloy components. Compared to the conventional routes, which typically require extensive material removal of forged billets, NNS methods offer more efficient material usage and can significantly reduce machining requirements. Furthermore, NNS manufacturing processes offer benefits such as greater flexibility and reduced costs compared to conventional methods. Processes such as metal additive manufacturing (AM) have started to be adopted in niche applications, most notably for the manufacture of medical implants, where many conventionally forged components have been replaced by those manufactured by AM processes. However, for more widespread adoption of these emerging processes, an improvement in the confidence in the techniques by manufacturers is necessary. This requires addressing challenges such as the limited mechanical properties of parts in their as-built condition compared to wrought products and the post-process machining requirements of components manufactured by these routes. In this review, processes which use a powder or wire feedstock are evaluated to assess their capabilities for the manufacture of titanium alloy components. These processes include powder bed fusion and direct energy deposition metal additive processes as well as hybrid routes, which combine powder metallurgy with thermomechanical post-processing.

Anwendungszentrum für additive Fertigung/Center for Applied Additive Manufacturing – Influence of process parameters during high-speed laser direct energy deposition

2021 ◽  
Vol 111 (06) ◽  
pp. 368-371
Author(s):  
Sebastian Greco ◽  
Marc Schmidt ◽  
Benjamin Kirsch ◽  
Jan C. Aurich
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Energy Deposition ◽  
Influence Of Process Parameters ◽  
Direct Energy Deposition ◽  
Additive Fertigung ◽  
Powder Bed ◽  
High Productivity ◽  
Direct Energy ◽  
Near Net Shape

Additive Fertigungsverfahren zeichnen sich durch die Möglichkeit der endkonturnahen Fertigung komplexer Geometrien aus. Die geringe Produktivität etablierter Verfahren wie etwa dem Pulverbettverfahren hemmen aktuell den wirtschaftlichen Einsatz additiver Fertigung. Das Hochgeschwindigkeits-Laserauftragschweißen (HLA) soll durch deutlich erhöhte Auftragsraten und somit bisher unerreicht hoher Produktivität bei der additiven Fertigung dazu beitragen, deren Wirtschaftlichkeit zu steigern.   Additive manufacturing enables the near-net-shape production of complex geometries. The low productivity of established processes such as powder bed processes is currently limiting the economic use of additive manufacturing. High-speed laser direct energy deposition (HS LDED) is expected to improve the economic efficiency of additive manufacturing by significantly increasing deposition rates and thus previously unattained high productivity.

The Additive Manufacturing (AM) of Titanium Alloys

2014 ◽  
Vol 1019 ◽  
pp. 19-25 ◽  
Author(s):  
F.H. Froes ◽  
B. Dutta
Keyword(s):  
Additive Manufacturing ◽  
Titanium Alloys ◽  
Cost Effective ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Processed Material ◽  
Cost Effective Approach ◽  
Direct Energy ◽  
Cad Cam ◽  
Near Net Shape

High cost is the major reason that there is not more wide-spread use of titanium alloys. Powder Metallurgy (P/M) represents one cost effective approach to fabrication of titanium components and Additive Manufacturing (AM) is an emerging attractive PM Technique . In this paper AM is discussed with the emphasis on the “work horse” titanium alloy Ti-6Al-4V. The various approaches to AM are presented and discussed, followed by some examples of components produced by AM. The microstructures and mechanical properties of Ti-6Al-4V produced by AM are listed and shown to compare very well with cast and wrought product. Finally, the economic advantages to be gained using the AM technique compared to conventionally processed material are presented. Key words: Additive Manufacturing (AM), 3D Printing, CAD, CAM, Laser, Electron beam, near net shape, remanufacturing, Powder Bed Fusion (PBF), Direct Energy Deposition (DED)

The Environmental Impacts of Metal Powder Bed Additive Manufacturing

2020 ◽  
Vol 143 (3) ◽  
Author(s):  
Jiankan Liao ◽  
Daniel R. Cooper
Keyword(s):  
Additive Manufacturing ◽  
Environmental Impacts ◽  
Metal Powder ◽  
Future Research ◽  
Research Directions ◽  
Powder Bed ◽  
Direct Energy ◽  
Potential Benefits ◽  
Future Research Directions ◽  
Am Processes

Abstract Additive manufacturing (AM) is widely recognized as a critical pillar of advanced manufacturing and is moving from the design shop to the factory floor. As AM processes become more popular, it is paramount that engineers and policymakers understand and then reduce their environmental impacts. This article structures the current work on the environmental impacts of metal powder bed processes: selective laser melting (SLM), direct metal laser sintering (DMLS), electron beam melting (EBM), and binder jetting (BJ). We review the potential benefits and pitfalls of AM in each phase of a part's lifecycle and in different application domains (e.g., remanufacturing and hybrid manufacturing). We highlight critical uncertainties and future research directions throughout. The environmental impacts of AM are sensitive to the specific production and use-phase context; however, several broad lessons can be extracted from the literature. Unlike in conventional manufacturing, powder bed production impacts are dominated by the generation of the direct energy (electricity) required to operate the AM machines. Combined with a more energy-intensive feedstock (metal powder), this means that powder bed production impacts are higher than in conventional manufacturing unless production volumes are very small (saving tool production impacts), and/or there are significant material savings through part light weighting or improved buy-to-fly ratios.

Comparing the Sustainability Performance of Metal-Based Additive Manufacturing Processes

2017 ◽  
Author(s):  
Rothanak Chan ◽  
Sriram Manoharan ◽  
Karl R. Haapala
Keyword(s):  
Additive Manufacturing ◽  
Evaluation Method ◽  
Bottom Line ◽  
Powder Bed ◽  
Sustainability Performance ◽  
Quantitative Metrics ◽  
Direct Energy ◽  
Approach Method ◽  
Am Processes ◽  
Wire Feed

While there have been many advancements in additive manufacturing (AM) technologies for metal products, there has not been a great deal of attention paid toward developing an understanding of the relative sustainability performance of various AM processes for production of aerospace components, such as wire feed and powder bed fusion processes. This research presents a method to calculate and compare quantitative metrics for evaluating metal AM process on a basis of sustainability performance. The process-level evaluation method encompasses a triple bottom line analysis for low volume part production. A representative aerospace titanium alloy (Ti-6Al-4V) component is considered for the study and the production of the part is modeled using direct energy deposition (DED) as the representative wire feed AM process and selective laser melting (SLM) as the representative powder bed AM process. The results indicate that DED has a superior sustainability performance to SLM, mainly due to the relatively slower deposition rate and higher cost of material for SLM than DED. This research provides decision makers an approach method and a demonstrated case study in comparing DED and SLM AM processes. This understanding reveals advantages between the two options and offers avenues of future investigation for these technologies for further development and larger scale use.

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.

Basic Study on Remelting Process to Enhance Density of Inconel 625 in Direct Energy Deposition

2018 ◽  
Vol 12 (3) ◽  
pp. 424-433 ◽  
Author(s):  
Ryo Koike ◽  
Taro Misawa ◽  
Yasuhiro Kakinuma ◽  
Yohei Oda ◽  
◽  
...  
Keyword(s):  
High Pressure ◽  
Energy Deposition ◽  
Laser System ◽  
Inconel 625 ◽  
Special Equipment ◽  
Direct Energy Deposition ◽  
Pore Evolution ◽  
Direct Energy ◽  
Am Processes ◽  
Production Conditions

Although the applicability of additive manufacturing (AM) to the production of complex shapes has attracted attention from the automobile and aerospace industries, companies hesitate to introduce AM processes because of their low reliability, which is due to pores inside the produced parts. Consequently, many researchers have experimentally evaluated the relation between the pore evolution and production conditions in AM processes. On the other hand, several studies have focused on finishing processes in order to enhance the quality of AM production, considering that production quality cannot be improved enough only by modifying the production conditions in AM processes. To reduce pores in a metal product, hot isostatic pressing (HIP), which applies high pressure and heat energy to metal AM products and enhances production density, has proven to be an efficient approach. However, special equipment is required to produce a high-temperature and high-pressure environment, leading to high cost and low productivity. From the view point of practicability, a simple finishing process would be a fundamental solution to make metal AM processes highly reliable. This paper therefore proposes a method of reducing pores through a remelting process in the direct energy deposition of Inconel 625. Furthermore, a method of doing a graphical analysis to evaluate the bias of pore distribution in the deposited object is proposed. The pore reduction effect in remelting is experimentally evaluated by irradiating the low density area with a laser beam, and a graphical evaluation clarifies that the concentration of residual pores occurs in the top layer of a deposited object. As a result, residual pores are eliminated with certainty through the remelting process. The density of the deposit can be enhanced easily and without any complicated finishing systems with just the laser system originally introduced in a DED machine.

scholarly journals Machine Learning for Competitive Grain Growth Behavior in Additive Manufacturing Ti6Al4V

2020 ◽  
Vol 321 ◽  
pp. 03004
Author(s):  
Jinghao Li ◽  
Manuel Sage ◽  
Xianglin Zhou ◽  
Mathieu Brochu ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Additive Manufacturing ◽  
Grain Boundary ◽  
Grain Growth ◽  
Manufacturing Industry ◽  
Energy Deposition ◽  
Growth Behavior ◽  
Direct Energy Deposition ◽  
Direct Energy ◽  
Grain Growth Behavior ◽  
Metal Additive

Metal additive manufacturing (MAM) technology is now changing the pattern of the high-end manufacturing industry, among which MAM fabricated Ti6Al4V has been far the most extensively investigated material and attracts a lot of research interests. This work established a deep neural network (DNN) to investigate the grain boundary in competitive grain growth for a bi-crystal system, the column β grains of Ti6Al4V as an example. Because of the limited number of experimental samples, the DNN is trained based on the data coming from the Geometrical Limited criterion. A series of direct energy deposition experiment using Ti6Al4V is carried out under the Taguchi experimental design. The grain boundary angles between the column grains are measured in the experiment and used to evaluate the accuracy of DNN.

scholarly journals Sensor-Based Additive Manufacturing Technologies

2021 ◽  
Vol 12 (3) ◽  
pp. 3513-3521
Keyword(s):  
Additive Manufacturing ◽  
Wearable Sensors ◽  
Sensor Technology ◽  
Layer By Layer ◽  
Environmental Sensors ◽  
Direct Energy Deposition ◽  
Powder Bed ◽  
Direct Energy ◽  
Building Components ◽  
Manufacturing Technologies

Additive manufacturing is the term that uses the CAD data to build components layer by layer; it is also termed layered manufacturing or 3D printing. The major advantage of additive manufacturing is the capability of building components without the use of molds or tools. Five major categories of AM processes include Powder Bed Fusion (PBF), Direct Energy Deposition (DED), Material Jetting (MJ), Binder Jetting (BJ), and Sheet Lamination (SL). The sensor may be defined as a device that responds to a physical stimulus and transmits a resulting impulse. Sensor technology has been widely adopted in advanced manufacturing, aerospace, biomedical and robotic applications. Commonly used sensors are temperature sensors, strain sensors, biosensors, environmental sensors, and wearable sensors, etc. Additive manufacturing technologies can fabricate sensors and microfluidic devices with less labor. This paper focuses on various sensors developed by additive manufacturing processes, and their practical application for the particular purpose is reviewed.

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