scholarly journals Metal Additive Manufacturing by Powder Blown Beam Deposition Process

2019 ◽  
Vol 9 (2) ◽  
pp. 5291-5304
Keyword(s):  
Additive Manufacturing ◽  
Deposition Process ◽  
Functionally Graded ◽  
Metal Foil ◽  
Layer By Layer ◽  
Graded Materials ◽  
Available Technology ◽  
Materials Used ◽  
Testing Standards ◽  
Beam Deposition

Additive Manufacturing (AM) is a tool less manufacturing process for building complex components layer by layer. Powder based AM techniques are used for producing porous and dense parts or products by Powder Bed Fusion (PBF) and powder blown Beam Deposition (BD) processes respectively suitable for different applications. The present review is mainly focused on the commercially available technology of powder blown Beam Deposition (BD) process for producing fully dense parts, and functionally graded materials used in automotive, aerospace, defense, and nuclear reactors. The properties of BD parts and comparison of the properties of BD parts with Selective Laser Melting (SLM), casting, and Acram's Electron Beam Melting (EBM) parts are presented. This paper provides an insight into the microstructural characteristics and mechanical properties of parts produced by BD process. A brief discussion is presented on challenging issues and applications of BD process. An attempt is made to present available and under development AM testing standards used to evaluate the properties of AM parts. This review also focused on porous parts produced by BD process for medical applications, and metal foil based BD process. Here, new developments in AM process like hybrid manufacturing and 4D printing are also discussed

scholarly journals Call for papers on special issue “Advances in additive manufacturing: modeling, design, and application”

2020 ◽  
Vol 2 (1) ◽  
pp. 048-048
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Industry ◽  
Low Cost ◽  
Functionally Graded ◽  
Layer By Layer ◽  
Special Issue ◽  
High Quality Research ◽  
Graded Materials ◽  
3D Printers ◽  
New Applications

Aim & Scope: Additive Manufacturing (AM) is revolutionizing the manufacturing industry. Building parts layer by layer makes fabrication of geometries which were impossible otherwise. Freedom of fabrication, rapid and low-cost prototyping, and reduction in material waste are only a few of advantages that AM offers to many industries from biomedical to aeronautics. Hence, AM is getting lots of interest over the past few years. These combined with lower cost of 3d printers is making this pace even faster. To keep up with the advancements in AM, this special issue aims to publish high quality research articles in the field of additive manufacturing and its related topics. This includes but not limited to alloy design for AM, new AM technologies and process optimization, process-microstructure-property, characterization of AM parts, modeling AM processes, topology optimization, fatigue, fracture, and failure analysis, tailoring properties, and functionally graded materials through AM. New applications are welcome, as well. We kindly invite you to submit a manuscript(s) for this Special Issue. Full papers, communications, and reviews are all welcome.

Design of a New Parametric Path Plan for Additive Manufacturing of Hollow Porous Structures With Functionally Graded Materials

2014 ◽  
Vol 14 (4) ◽  
Author(s):  
Ibrahim T. Ozbolat ◽  
A. K. M. B. Khoda
Keyword(s):  
Additive Manufacturing ◽  
Path Planning ◽  
Functionally Graded Materials ◽  
Three Dimensional ◽  
Functionally Graded ◽  
Relaxation Techniques ◽  
Layer By Layer ◽  
Porous Structures ◽  
Graded Materials ◽  
Voronoi Regions

In this paper, a novel path planning approach is proposed to generate porous structures with internal features. The interconnected and continuous deposition path is designed to control the internal material composition in a functionally graded manner. The proposed layer-based algorithmic solutions generate a bilayer pattern of zigzag and spiral toolpath consecutively to construct heterogeneous three-dimensional (3D) objects. The proposed strategy relies on constructing Voronoi diagrams for all bounding curves in each layer to decompose the geometric domain and discretizing the associated Voronoi regions with ruling lines between the boundaries of the associated Voronoi regions. To avoid interference among ruling lines, reorientation and relaxation techniques are introduced to establish matching for continuous zigzag path planning. In addition, arc fitting is used to reduce over-deposition, allowing nonstop deposition at sharp turns. Layer-by-layer deposition progresses through consecutive layers of a ruling-line-based zigzag pattern followed by a spiral path deposition. A biarc fitting technique is employed through isovalues of ruling lines to generate G1 continuity along the spiral deposition path plan. Functionally graded material properties are then mapped based on a parametric distance-based weighting technique. The proposed approach enables elimination or minimization of over-deposition of materials, nonuniformity on printed strands and discontinuities on the toolpath, which are shortcomings of traditional zigzag-based toolpath plan in additive manufacturing (AM). In addition, it provides a practical path for printing functionally graded materials.

Additive Manufacturing of Multi-Material and Composite Parts

2020 ◽  
pp. 127-146
Author(s):  
V. Senthilkumar ◽  
Velmurugan C. ◽  
K. R. Balasubramanian ◽  
M. Kumaran
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Functionally Graded Materials ◽  
Deposition Process ◽  
Functionally Graded ◽  
Subsequent Stage ◽  
Functional Requirements ◽  
Graded Materials ◽  
Material Deposition ◽  
Single Part

Additive manufacturing (AM) technology can be employed to produce multimaterial parts. In this approach, multiple types of materials are used for the fabrication of a single part. Custom-built functionally graded, heterogeneous, or porous structures and composite materials can be fabricated thorough this process. In this method, metals, plastics, and ceramics have been used with suitable AM methods to obtain multi-material products depending on functional requirements. The process of making composite materials by AM can either be performed during the material deposition process or by a hybrid process in which the combination of different materials can be performed before or after AM as a previous or subsequent stage of production of a component. Composite processes can be employed to produce functionally graded materials (FGM).

scholarly journals WAAM and Other Unconventional Metal Additive Manufacturing Technologies

2020 ◽  
Vol 45 (2) ◽  
pp. 1-9
Author(s):  
Damjan Klobčar ◽  
Sebastijan Baloš ◽  
Matija Bašić ◽  
Aleksija Djurić ◽  
Maja Lindič ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Processing Parameters ◽  
Functionally Graded ◽  
High Deposition Rate ◽  
Graded Materials ◽  
Metal Additive Manufacturing ◽  
Ultrasonic Additive Manufacturing ◽  
Materials Used ◽  
Manufacturing Technologies ◽  
Metal Additive

The paper presents an overview of metal additive manufacturing technologies. The emphasis is on unconventional emerging technologies with firm background on welding technologies such as Ultrasonic Additive Manufacturing, Friction Additive Manufacturing, Thermal Spray Additive Manufacturing, Resistance Additive Manufacturing and Wire and Arc Additive Manufacturing. The particular processes are explained in detail and their advantages and drawbacks are presented. Attention is made on materials used, possibilities to produce multi-material products and functionally graded materials, and typical applications of currently developed technologies. The state-of-the-art on the Wire and Arc Additive Manufacturing is presented in more detail due to high research interests, it’s potential and widespread. The main differences between different arc additive manufacturing technologies are shown. An influence of processing parameters is discussed with respect to process stability and process control. The challenges related to path planning are shown together with the importance of post-processing. The main advantage of presented technologies is their ability of making larger and multi-material parts, with high deposition rate, which is difficult to achieve using conventional additive technologies.

scholarly journals Ceramic-Based 4D Components: Additive Manufacturing (AM) of Ceramic-Based Functionally Graded Materials (FGM) by Thermoplastic 3D Printing (T3DP)

Materials ◽  
2017 ◽  
Vol 10 (12) ◽  
pp. 1368 ◽  
Author(s):  
Uwe Scheithauer ◽  
Steven Weingarten ◽  
Robert Johne ◽  
Eric Schwarzer ◽  
Johannes Abel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Functionally Graded Materials ◽  
Functionally Graded ◽  
Graded Materials

Approximate Functionally Graded Materials for Multi-Material Additive Manufacturing

2018 ◽  
Author(s):  
Yuen-Shan Leung ◽  
Huachao Mao ◽  
Yong Chen
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Functionally Graded Materials ◽  
Functionally Graded ◽  
Gradual Transition ◽  
Material Distribution ◽  
Graded Materials ◽  
Base Materials ◽  
Multiple Materials ◽  
Am Processes

Functionally graded materials (FGM) possess superior properties of multiple materials due to the continuous transitions of these materials. Recent progresses in multi-material additive manufacturing (AM) processes enable the creation of arbitrary material composition, which significantly enlarges the manufacturing capability of FGMs. At the same time, the fabrication capability also introduces new challenges for the design of FGMs. A critical issue is to create the continuous material distribution under the fabrication constraints of multi-material AM processes. Using voxels to approximate gradient material distribution could be one plausible way for additive manufacturing. However, current FGM design methods are non-additive-manufacturing-oriented and unpredictable. For instance, some designs require a vast number of materials to achieve continuous transitions; however, the material choices that are available in a multi-material AM machine are rather limited. Other designs control the volume fraction of two materials to achieve gradual transition; however, such transition cannot be functionally guaranteed. To address these issues, we present a design and fabrication framework for FGMs that can efficiently and effectively generate printable and predictable FGM structures. We adopt a data-driven approach to approximate the behavior of FGM using two base materials. A digital material library is constructed with different combinations of the base materials, and their mechanical properties are extracted by Finite Element Analysis (FEA). The mechanical properties are then used for the conversion process between the FGM and the dual material structure such that similar behavior is guaranteed. An error diffusion algorithm is further developed to minimize the approximation error. Simulation results on four test cases show that our approach is robust and accurate, and the framework can successfully design and fabricate such FGM structures.

Additive manufacturing of Inconel625-HSLA Steel functionally graded material by wire arc additive manufacturing

2021 ◽  
Vol 118 (5) ◽  
pp. 502
Author(s):  
Jiarong Zhang ◽  
Xinjie Di ◽  
Chengning Li ◽  
Xipeng Zhao ◽  
Lingzhi Ba ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Chemical Composition ◽  
Primary Dendrite ◽  
Hsla Steel ◽  
High Strength ◽  
Phase Evolution ◽  
Functionally Graded ◽  
Graded Materials ◽  
Graded Material ◽  
Wire Arc Additive Manufacturing

Functional graded materials (FGMs) have been widely applied in many engineering fields, and are very potential to be the substitutions of dissimilar metal welding joints due to their overall performance. In this work, the Inconel625-high-strength low-alloy (HSLA) Steel FGM was fabricated by wire arc additive manufacturing (WAAM). The chemical composition distribution, microstructure, phase evolution and mechanical properties of the FGM were examined. With the increasing of HSLA Steel, the chemical composition appeared graded distribution, and the primary dendrite spacing was largest in graded region with 20%HSLA Steel and then gradually decreased. And the main microstructure of the FGM transformed from columnar dendrites to equiaxed dendrites. Laves phase precipitated along dendrites boundary when the content of HSLA Steel was lower than 70% and Nb-rich carbides precipitated when the content of HSLA Steel exceeded to 70%. Microhardness and tensile strength gradually decreased with ascending content of HSLA Steel, and had a drastic improvement (159HV to 228HV and 355Mpa to 733Mpa) when proportion of HSLA Steel increased from 70% to 80%.

A Novel Transition Region Representation for Additive Manufacturing for Graded Materials, Structures and Tolerances

2017 ◽  
Author(s):  
Gaurav Ameta ◽  
Paul Witherell
Keyword(s):  
Additive Manufacturing ◽  
Transition Region ◽  
Heterogeneous Materials ◽  
Functionally Graded ◽  
Material Distribution ◽  
Graded Materials ◽  
Explicit Material ◽  
Novel Method ◽  
Multiple Material ◽  
Region Representation

Additive manufacturing (AM) has enabled control over heterogeneous materials in ways that were not previously possible. This paper presents a novel method for representing and communicating heterogeneous materials based structures that include tolerancing of geometry and material together. AM has expanded design possibilities to include specified material heterogeneities, including functionally graded materials. The aim of the paper is to propose a means to specify nominal materials and allowable material variations in parts, including (a) explicit material transitions and (b) functional transitions to support single and multiple material behaviors. The transition region combines bounded regions (volumes and surfaces) and material distribution equations. Tolerancing is defined at two levels, that of the geometry including bounded regions and that of the materials. Material tolerances are defined as allowable material variations from nominal material fractions within a unit volume at a given location computed using material distribution equations. The method is described thorough several case studies of abrupt transitions, lattice based transitions, and multi-material transitions.

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