Plasma Metal Deposition for Metallic Materials

Plasma metal deposition (PMD®) is a promising and economical direct energy deposition technique for metal additive manufacturing based on plasma as an energy source. This process allows the use of powder, wire, or both combined as feedstock material to create near-net-shape large size components (i.e., >1 m) with high-deposition rates (i.e., 10 kg/h). Among the already PMD® processed materials stand out high-temperature resistance nickel-based alloys, diverse steels and stainless steels commonly used in the industry, titanium alloys for the aerospace field, and lightweight alloys. Furthermore, the use of powder as feedstock also allows to produce metal matrix composites reinforced with a wide range of materials. This chapter presents the characteristics of the PMD® technology, the welding parameters affecting additive manufacturing, examples of different fabricated materials, as well as the challenges and developments of the rising PMD® technology.

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

wt Werkstattstechnik online ◽

10.37544/1436-4980-2021-06-12 ◽

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.

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Additive Layer Manufacturing using Metal Deposition

Metals ◽

10.3390/met10040459 ◽

2020 ◽

Vol 10 (4) ◽

pp. 459

Author(s):

Patrice Peyre

Keyword(s):

Additive Manufacturing ◽

Laser Cladding ◽

Energy Deposition ◽

Metal Deposition ◽

Direct Energy Deposition ◽

Additive Layer Manufacturing ◽

Layer Manufacturing ◽

Direct Energy ◽

Wire Feeding ◽

Manufacturing Techniques

Among the additive layer manufacturing techniques for metals, those involving metal deposition, including laser cladding/Direct Energy Deposition (DED, with powder feeding) or Wire and Arc Additive Manufacturing (WAAM, with wire feeding), exhibit several attractive features [...]

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Non-destructive quality control methods in additive manufacturing: a survey

Rapid Prototyping Journal ◽

10.1108/rpj-08-2019-0224 ◽

2020 ◽

Vol 26 (4) ◽

pp. 777-790 ◽

Cited By ~ 1

Author(s):

Paschalis Charalampous ◽

Ioannis Kostavelis ◽

Dimitrios Tzovaras

Keyword(s):

Quality Control ◽

Additive Manufacturing ◽

Complex Objects ◽

Destructive Testing ◽

Content Type ◽

Wide Range ◽

Manufacturing Procedure ◽

Direct Energy ◽

Non Destructive

Purpose In recent years, additive manufacturing (AM) technology has been acknowledged as an efficient method for producing geometrical complex objects with a wide range of applications. However, dimensional inaccuracies and presence of defects hinder the broad adaption of AM procedures. These factors arouse concerns regarding the quality of the products produced with AM and the utilization of quality control (QC) techniques constitutes a must to further support this emerging technology. This paper aims to assist researchers to obtain a clear sight of what are the trends and what has been inspected so far concerning non-destructive testing (NDT) QC methods in AM. Design/methodology/approach In this paper, a survey on research advances on non-destructive QC procedures used in AM technology has been conducted. The paper is organized as follows: Section 2 discusses the existing NDT methods applied for the examination of the feedstock material, i.e. incoming quality control (IQC). Section 3 outlines the inspection methods for in situ QC, while Section 4 presents the methods of NDT applied after the manufacturing process i.e. outgoing QC methods. In Section 5, statistical QC methods used in AM technologies are documented. Future trends and challenges are included in Section 6 and conclusions are drawn in Section 7. Findings The primary scope of the study is to present the available and reliable NDT methods applied in every AM technology and all stages of the process. Most of the developed techniques so far are concentrated mainly in the inspection of the manufactured part during and post the AM process, compared to prior to the procedure. Moreover, material extrusion, direct energy deposition and powder bed processes are the focal points of the research in NDT methods applied in AM. Originality/value This literature review paper is the first to collect the latest and the most compatible techniques to evaluate the quality of parts produced by the main AM processes prior, during and after the manufacturing procedure.

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The Additive Manufacturing (AM) of Titanium Alloys

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1019.19 ◽

2014 ◽

Vol 1019 ◽

pp. 19-25 ◽

Cited By ~ 29

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)

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Microstructure and Properties of 3D Ti-6Al-4V Articles Produced with Advanced Co-axial Electron Beam & Wire Additive Manufacturing Technology

MATEC Web of Conferences ◽

10.1051/matecconf/202032103014 ◽

2020 ◽

Vol 321 ◽

pp. 03014

Author(s):

Dmytro Kovalchuk ◽

Orest Ivasishin ◽

Dmytro Savvakin

Keyword(s):

Electron Beam ◽

Additive Manufacturing ◽

Liquid Metal ◽

Low Voltage ◽

Processing Parameters ◽

Manufacturing Technology ◽

Additive Manufacturing Technology ◽

Direct Energy ◽

Material Texture ◽

Feedstock Material

Ti-6Al-4V articles were produced with advanced additive manufacturing technology of Direct Energy Deposition (DED) type using profile electron beam and wire as feedstock material. The key distinctive feature of this additive manufacturing process is the applying of the hollow conical electron beam generated by low-voltage (<20kV) gas-discharge EB gun for heating and melting of the substrate and co-axially fed wire. Such configuration ensures precisely controllable liquid metal transfer from the wire end to the substrate, specific temperature gradients at the fusion area and heat flow from liquid metal pool. Such conditions of heating, melting and cooling during 3D manufacturing processing provide the ability for controllable microstructure formation, including grain size and material texture. Influence of processing parameters and cooling conditions on crystallization, grain formation and intragrain structure of solidified material is discussed. Optimization of processing parameters allowed production of 3D Ti-6Al- 4V articles with isotropic microstructure and mechanical properties which met standard requirements for Ti-6Al-4V alloy.

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Orientation Effects on Fatigue Behavior of Additively Manufactured Stainless Steel

Volume 6A: Materials and Fabrication ◽

10.1115/pvp2017-65948 ◽

2017 ◽

Cited By ~ 2

Author(s):

Thale R. Smith ◽

Joshua D. Sugar ◽

Chris San Marchi ◽

Julie M. Schoenung

Keyword(s):

Stainless Steel ◽

Additive Manufacturing ◽

Fatigue Testing ◽

Fatigue Behavior ◽

Build Orientation ◽

Design Flexibility ◽

Deposition Parameters ◽

Design Choice ◽

Direct Energy ◽

Near Net Shape

Direct energy deposition (DED) is an additive manufacturing process that can produce complex near-net shape metallic components in a single manufacturing step. DED additive manufacturing has the potential to reduce feedstock material waste, streamline manufacturing chains, and enhance design flexibility. A major impediment to broader acceptance of DED technology is limited understanding of defect populations in the novel microstructures produced by DED and their relationship to process parameters and resultant mechanical properties. A design choice as simple as changing the build orientation has been observed to result in differences as great as ∼25% in yield strength for type 304L austenitic stainless steel deposited with otherwise identical deposition parameters. To better understand the role of build orientation and resultant defect populations on fatigue behavior in DED 304L, tension-tension fatigue testing has been performed on circumferentially notched cylindrical test specimens extracted from both vertical and horizontal orientations relative to the build direction. Notched fatigue behavior was found to be strongly influenced by the manufacturing defect populations of the material for different build orientations.

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Direct metal deposition of titanium matrix composites using B4C powder

International Congress on Applications of Lasers & Electro-Optics ◽

10.2351/1.5063239 ◽

2015 ◽

Author(s):

S. Pouzet ◽

P. Peyre ◽

C. Gorny ◽

O. Castelnau ◽

T. Baudin ◽

...

Keyword(s):

Metal Deposition ◽

Direct Metal Deposition ◽

Matrix Composites ◽

Titanium Matrix ◽

Titanium Matrix Composites ◽

B4c Powder

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Geometry and Distortion Prediction of Multiple Layers for Wire Arc Additive Manufacturing with Artificial Neural Networks

Applied Sciences ◽

10.3390/app11104694 ◽

2021 ◽

Vol 11 (10) ◽

pp. 4694

Author(s):

Christian Wacker ◽

Markus Köhler ◽

Martin David ◽

Franziska Aschersleben ◽

Felix Gabriel ◽

...

Keyword(s):

Additive Manufacturing ◽

Welding Process ◽

High Energy ◽

Welding Distortion ◽

Direct Energy Deposition ◽

Direct Energy ◽

Industrial Use ◽

Artificial Neural ◽

Artificial Neural Network Ann ◽

Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process with high deposition rates, but deformation and distortion can occur due to the high energy input and resulting strains. Despite great efforts, the prediction of distortion and resulting geometry in additive manufacturing processes using WAAM remains challenging. In this work, an artificial neural network (ANN) is established to predict welding distortion and geometric accuracy for multilayer WAAM structures. For demonstration purposes, the ANN creation process is presented on a smaller scale for multilayer beads on plate welds on a thin substrate sheet. Multiple concepts for the creation of ANNs and the handling of outliers are developed, implemented, and compared. Good results have been achieved by applying an enhanced ANN using deformation and geometry from the previously deposited layer. With further adaptions to this method, a prediction of additive welded structures, geometries, and shapes in defined segments is conceivable, which would enable a multitude of applications for ANNs in the WAAM-Process, especially for applications closer to industrial use cases. It would be feasible to use them as preparatory measures for multi-segmented structures as well as an application during the welding process to continuously adapt parameters for a higher resulting component quality.

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