Additive Manufacturing

2019 ◽  
pp. 165-183 ◽  
Author(s):  
Kamardeen Olajide Abdulrahman ◽  
Esther T. Akinlabi ◽  
Rasheedat M. Mahamood
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Titanium Aluminide ◽  
Three Dimensional ◽  
Physical And Mechanical Properties ◽  
Processing Parameters ◽  
Metal Deposition ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
Additive Process

Three-dimensional printing has evolved into an advanced laser additive manufacturing (AM) process with capacity of directly producing parts through CAD model. AM technology parts are fabricated through layer by layer build-up additive process. AM technology cuts down material wastage, reduces buy-to-fly ratio, fabricates complex parts, and repairs damaged old functional components. Titanium aluminide alloys fall under the group of intermetallic compounds known for high temperature applications and display of superior physical and mechanical properties, which made them most sort after in the aeronautic, energy, and automobile industries. Laser metal deposition is an AM process used in the repair and fabrication of solid components but sometimes associated with thermal induced stresses which sometimes led to cracks in deposited parts. This chapter looks at some AM processes with more emphasis on laser metal deposition technique, effect of LMD processing parameters, and preheating of substrate on the physical, microstructural, and mechanical properties of components produced through AM process.

scholarly journals Build-up strategies for additive manufacturing of three dimensional Ti-6Al-4V-parts produced by laser metal deposition

2018 ◽  
Vol 30 (2) ◽  
pp. 022001 ◽  
Author(s):  
Felix Spranger ◽  
Benjamin Graf ◽  
Michael Schuch ◽  
Kai Hilgenberg ◽  
Michael Rethmeier
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Metal Deposition ◽  
Laser Metal Deposition

scholarly journals Experimental Investigation on Mechanical Properties of Part Fabricated by Wire Arc Additive Manufacturing Process

2021 ◽  
Author(s):  
Vivek Kumar P ◽  
◽  
Soundrapandian E ◽  
Jenin Joseph A ◽  
Kanagarajan E ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Three Dimensional ◽  
Casting Process ◽  
Significant Rise ◽  
Layer By Layer ◽  
Cnc Machine ◽  
Hardness Tester ◽  
Wire Arc Additive Manufacturing

Additive manufacturing process is a method of layer by layer joining of materials to create components from three-dimensional (3D) model data. After their introduction in the automotive sector a decade ago, it has seen a significant rise in research and growth. The Additive manufacturing is classified into different types based upon the energy source use in the fabrication process. In our project, we used self-build CNC machine that runs MACH3 software, as well as the MACH3 controller is used to control the welding torch motion for material addition through three axis movement (X, Y and Z). In the project we used ER70 S-6 weld wire for the fabrication and examined its microstructure and mechanical properties. Different layers of the specimen had different microstructures, according to microstructural studies of the product. Rockwell hardness tester used for testing hardness of the product. According to the observation of the part fabricated components using the Wire Arc Additive Manufacturing process outperformed the mechanical properties of mild steel casting process. The product fabricated by Wire Arc Additive Manufacturing process properties is superior to conventional casting process.

Spatial Iterative Learning Control for Multi-material Three-Dimensional Structures

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Zahra Afkhami ◽  
Christopher Pannier ◽  
Leontine Aarnoudse ◽  
David Hoelzle ◽  
Kira Barton
Keyword(s):  
Additive Manufacturing ◽  
Iterative Learning Control ◽  
Initial Conditions ◽  
Three Dimensional ◽  
Single Layer ◽  
Learning Control ◽  
Iterative Learning ◽  
Layer By Layer ◽  
Additive Process ◽  
Jet Printing

Abstract Iterative learning control (ILC) is a powerful technique to regulate repetitive systems. Additive manufacturing falls into this category by nature of its repetitive action in building three-dimensional structures in a layer-by-layer manner. In literature, spatial ILC (SILC) has been used in conjunction with additive processes to regulate single-layer structures with only one class of material. However, SILC has the unexplored potential to regulate additive manufacturing structures with multiple build materials in a three-dimensional fashion. Estimating the appropriate feedforward signal in these structures can be challenging due to iteration varying initial conditions, system parameters, and surface interaction dynamics in different layers of multi-material structures. In this paper, SILC is used as a recursive control strategy to iteratively construct the feedforward signal to improve part quality of 3D structures that consist of at least two materials in a layer-by-layer manner. The system dynamics are approximated by discrete 2D spatial convolution using kernels that incorporate in-layer and layer-to-layer variations. We leverage the existing SILC models in literature and extend them to account for the iteration varying uncertainties in the plant model to capture a more reliable representation of the multi-material additive process. The feasibility of the proposed diagonal framework was demonstrated using simulation results of an electrohydrodynamic jet printing (e-jet) printing process.

Laser Metal Deposition Additive Manufacturing of TiC Reinforced Inconel 625 Composites: Influence of the Additive TiC Particle and Its Starting Size

2016 ◽  
Vol 139 (4) ◽  
Author(s):  
Dongdong Gu ◽  
Sainan Cao ◽  
Kaijie Lin
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Central Zone ◽  
Metal Deposition ◽  
Inconel 625 ◽  
Wear Property ◽  
Laser Metal Deposition ◽  
Inconel 625 Alloy ◽  
Tic Particle ◽  
Original Size

In this study, laser metal deposition (LMD) additive manufacturing was used to deposit the pure Inconel 625 alloy and the TiC/Inconel 625 composites with different starting sizes of TiC particles, respectively. The influence of the additive TiC particle and its original size on the constitutional phases, microstructural features, and mechanical properties of the LMD-processed parts was studied. The incorporation of TiC particles significantly changed the prominent texture of Ni–Cr matrix phase from (200) to (100). The bottom and side parts of each deposited track showed mostly the columnar dendrites, while the cellular dendrites were prevailing in the microstructure of the central zone of the deposited track. As the nano-TiC particles were added, more columnar dendrites were observed in the solidified molten pool. The incorporation of nano-TiC particles induced the formation of the significantly refined columnar dendrites with the secondary dendrite arms developed considerably well. With the micro-TiC particles added, the columnar dendrites were relatively coarsened and highly degenerated, with the secondary dendrite growth being entirely suppressed. The cellular dendrites were obviously refined by the additive TiC particles. When the nano-TiC particles were added to reinforce the Inconel 625, the significantly improved microhardness, tensile property, and wear property were obtained without sacrificing the ductility of the composites.

Control Module of Laser Metal Deposition Shaping System

2011 ◽  
Vol 480-481 ◽  
pp. 644-649
Author(s):  
Kai Zhang ◽  
Xiao Feng Shang ◽  
Wei Jun Liu
Keyword(s):  
Motion Control ◽  
Computer Control ◽  
Processing Parameters ◽  
Metal Deposition ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
Control Module ◽  
Software Structure ◽  
Shaping System ◽  
Rapid Prototyping And Manufacturing

The Laser Metal Deposition Shaping (LMDS) is a state-of-the-art technology which correlates the Rapid Prototyping and Manufacturing (RP&M) and laser processing. During this process, a certain alloy is fused onto the surface of a substrate. Laser deposition devices, namely powder feeder, CNC worktable, and laser shutter, are integrated to automatically make any cladding profile possible. Material is deposited by scanning the laser across a surface while injecting metallic powders into the molten pool at the laser focus. The metal part is then fabricated layer by layer. The LMDS system consists of four primary components: energy supply module, motion control module, powder delivery module, and computer control module. These modules of LMDS system individually perform the specified functions, but coordinate with each other. One of them, the control module plays an important role in causing the LMDS system automatic and intelligent. The control module can be divided into hardware and software components. The hardware structure mainly includes industrial computer, motors, and motion control card, which build the overall framework, and are driven by software structure. The software structure, namely the system application program with GUI, can instruct every module of LMDS system to finish the motion cooperatively adjust the processing parameters freely, and fulfill the LMDS technology automatically and intelligently. The hardware and software structures work in harmony with each other, thus flexibly controlling the LMDS system.

scholarly journals Additive Manufacturing of H11 with Wire-Based Laser Metal Deposition

2017 ◽  
Vol 22 (4) ◽  
pp. 466-479 ◽  
Author(s):  
Stella Holzbach Oliari ◽  
Ana Sofia Clímaco Monteiro D’Oliveira ◽  
Martin Schulz
Keyword(s):  
Additive Manufacturing ◽  
Travel Speed ◽  
Metal Deposition ◽  
Parameters Optimization ◽  
Layer By Layer ◽  
Laser Metal Deposition ◽  
3D Cad ◽  
Deposition Parameters ◽  
Commercial Applications ◽  
Functional Components

Abstract Laser additive manufacturing (LAM) is a near-net-shape production technique by which a part can be built up from 3D CAD model data, without material removal. Recently, these production processes gained attention due to the spreading of polymer-based processes in private and commercial applications. However, due to the insufficient development of metal producing processes regarding design, process information and qualification, resistance on producing functional components with this technology is still present. To overcome this restriction further studies have to be undertaken. The present research proposes a parametric study of additive manufacturing of hot work tool steel, H11. The selected LAM process is wire-based laser metal deposition (LMD-W). The study consists of parameters optimization for single beads (laser power, travel speed and wire feed rate) as well as lateral and vertical overlap for layer-by-layer technique involved in LMD process. Results show that selection of an ideal set of parameters affects substantially the surface quality, bead uniformity and bond between substrate and clad. Discussion includes the role of overlapping on the soundness of parts based on the height homogeneity of each layer, porosity and the presence of gaps. For the conditions tested it was shown that once the deposition parameters are selected, lateral and vertical overlapping determines the integrity and quality of parts processed by LAM.

scholarly journals Additive Manufacturing of 316L Stainless Steel

2019 ◽  
Vol 8 (4) ◽  
pp. 6825-6829 ◽  
Keyword(s):  
Mechanical Properties ◽  
Stainless Steel ◽  
Additive Manufacturing ◽  
Computer Aided Design ◽  
316L Stainless Steel ◽  
Electrical Discharge Machining ◽  
Sheet Material ◽  
Physical And Mechanical Properties ◽  
Layer By Layer ◽  
Graded Material

Additive manufacturing (AM) is a process of making parts by adding ultrathin layers of materials such as liquid, powder or sheet material layer by layer using 3D printing machine with the aid of a computer-aided design (CAD) software from 3D model data. Intricate, complex parts with graded material can be fabricated with ease. However, additively manufactured parts can vary in physical and mechanical properties with conventionally manufactured parts. In this final year project, AM was done using metal powder of 316L stainless steel alloy owing to good corrosion resistance, ductility and strength. The main objectives for this project are to fabricate 316L stainless steel using AM and to study the physical and mechanical properties of the addictively manufactured specimens compared with electrical discharge machining (EDM) wire cut specimens. A standard specimen bone shaped were manufactured in accordance with ASTM E8 and followed by physical and mechanical testing. From the testing and analysis, 316L stainless steel samples manufactured via AM route have the ultimate tensile strength ranged from 514 to 520 MPa while EDM specimens ranged from 574 to 576 MPa, the yield strength of AM specimens ranged from 385 to 390 MPa while EDM specimens ranged from 350 to 355 MPa, and the average elongation at failure of AM specimens are 45% while EDM specimens are 66%. From this project, it shows that AM specimens have comparable physical and mechanical properties with EDM specimens.

Prediction of Mechanical Properties of Direct Metal Laser Sintered 15-5PH Steel Parts Using Bayesian Inference: A Preliminary Study

2019 ◽  
Author(s):  
Ala Qattawi ◽  
Durul Ulutan ◽  
Ala’aldin Alafaghani
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Statistical Approach ◽  
Processing Parameters ◽  
Training Dataset ◽  
Layer By Layer ◽  
Probabilistic Prediction ◽  
Testing Data ◽  
Preliminary Study ◽  
Prediction Of Mechanical Properties

Abstract Direct Metal Laser Sintering (DMLS) is an additive manufacturing process where metal parts are created layer by layer. Mechanical properties of the final product can vary significantly based on processing parameters. In traditional processes, such effects of processing parameters on mechanical properties are well-established. However, additive manufacturing methods are relatively new, which means there is less consensus, if at all, on how processing parameters affect mechanical properties of the final product. This study is a preliminary effort toward understanding the effects of processing parameters on mechanical properties of the metal. Processing parameters studied were the fabrication direction and temperature. Mechanical properties that were studied were the yield and tensile strength of the built material. 15-5PH stainless steel parts were DMLS fabricated with varying temperatures and directions for this purpose and their mechanical properties were measured. Then, a statistical approach was followed in order to generate a probabilistic prediction model. In this approach, Gibbs sampling was used to randomly sample from population of coefficients, Metropolis algorithm was used for decision-making purposes based on performance of different coefficient sets, and an empirical model was hypothesized. Then, the model was trained using a training dataset, and the cloud of coefficient sets for the hypothesized equation were obtained. Using these coefficient sets, the probable normal distribution of other test conditions was predicted and verified using testing data. It was shown that all measurements were well within the confidence interval of predictions, with a maximum difference of 4% between mean predictions and measurements. It was also observed that with a coefficient of variation smaller than 18%, spread of predictions was low enough to suggest that predictions were precise as well as their accuracy.

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