The Comparison of Microstructure and Mechanical Behavior of Stainless Steel 316L Using Near Net Shaped and Fully Embedded Methodologies Using DED Metal Advanced Manufacturing

The objective of this research is to compare the microstructure and mechanical behavior of 3D printed SS 316L using near net shaped and fully embedded manufacturing extraction techniques. Research findings will allow us to determine if two different manufacturing extraction methodologies of a 3D printed stainless steel part will affect the overall performance of test specimens. Research will implement advanced manufacturing, part designing, part modeling, part simulation, part production, CT X-ray scanning, material characterization, and material testing. Printing of test specimens will be done with a Optomec Lens 3D Hybrid Machine Tool Direct Energy Deposition (DED) metal printer. The DED metal printer will be used for prototype printing and printing test samples. The areas of study will also include modeling and design using SolidWorks CAD software. A comparison of printing orientation/configuration, internal composition, and testing of material structure in the areas of stress to complete failure of test specimens. The internal structure analysis will observe the porosity effects of 3D metal printing with near net shaped and cocoon style print parameters. The study will also address the amount of time, production, strength, composition, and overall performance of SS 316L printed material.

Feasibility evaluation of using additive technologies in aerospace products

The paper studies the feasibility of using additive technologies in the manufacture of parts of complex shapes for aerospace products. The results of the structural analysis of a part helped find the directions of topological optimization and optimize the part’s design. To confirm the relevance of the design optimization, we carried out static and dynamic strength calculations in the Siemens NX software package. The paper considers technologies for manufacturing the part by 3D metal printing and traditional milling on a numerically controlled machine. In order to obtain initial data for economic calculations, we simulated manufacturing processes in various software systems. To study the feasibility of metal printing technology, we carried out its technical and economic analysis, and found that the production program, technological processing modes and the cost of materials affect the cost of the product.

A Simple Method of Reducing Coolant Leakage for Direct Metal Printed Injection Mold with Conformal Cooling Channels Using General Process Parameters and Heat Treatment

Direct metal printing is a promising technique for manufacturing injection molds with complex conformal cooling channels from maraging steel powder, which is widely applied in automotive or aerospace industries. However, two major disadvantages of direct metal printing are the narrow process window and length of time consumed. The fabrication of high-density injection molds is frequently applied to prevent coolant leakage during the cooling stage. In this study, we propose a simple method of reducing coolant leakage for a direct-metal-printed injection mold with conformal cooling channels by combining injection mold fabrication with general process parameters, as well as solution and aging treatment (SAT). This study comprehensively investigates the microstructural evolution of the injection mold after SAT using field-emission scanning electron microscopy and energy-dispersive X-ray spectroscopy. We found that the surface hardness of the injection mold was enhanced from HV 189 to HV 546 as the Ni-Mo precipitates increased from 12.8 to 18.5%. The size of the pores was reduced significantly due to iron oxide precipitates because the relative density of the injection mold increased from 99.18 to 99.72%. The total production time of the wax injection mold without coolant leakage during the cooling stage was only 62% that of the production time of the wax injection mold fabricated with high-density process parameters. A significant savings of up to 46% of the production cost of the injection mold was obtained.

Boiling Enhanced Lidded Server Packages for Two-Phase Immersion Cooling Using 3D Metal Printing and Metal Injection Molding Technologies

In order to meet increasing performance demand from high-performance computing (HPC) and edge computing, thermal design power (TDP) of CPU and GPU needs to increase. This creates thermal challenge to corresponding electronic packages with respect to heat dissipation. In order to address this challenge, two-phase immersion cooling is gaining attention as its primary mode of heat of removal is via liquid-to-vapor phase change, which can occur at relatively low and constant temperatures. In this paper, integrated heat spreader (IHS) with boiling enhancement features is proposed. 3D metal printing and metal injection molding (MIM) are the two approaches used to manufacture the new IHS. The resultant IHS with enhancement features are used to build test vehicles (TV) by following standard electronic package assembly process. Experimental results demonstrated that boiling enhanced TVs improved two-phase immersion cooling capability by over 50% as compared to baseline TV without boiling enhanced features.

Advanced Corrosion Protection of Additive Manufactured Light Metals by Creating Ceramic SurfaceThrough CERANOD® Plasma Electrolytical Oxidation Process

Lightweight structures produced by additive manufacturing (AM) technology such as the selective laser melting (SLM) process enable the fabrication of 3D structures with a high degree of freedom. A printed component can be tailored to have specific properties and render possible applications for industries such as the aerospace and automotive industries. Here, AlSi10Mg is one of the alloys that is currently used for SLM processes. Although the research with the aim improving the strength of AM aluminum alloy components is rapidly progressing, corrosion protection is scarcely addressed in this field. Plasma electrolytic oxidation (PEO) is an advanced electrolytical process for surface treatment of light metals such as aluminum, magnesium, and titanium. This process produces an oxide ceramic-like layer, which is extremely hard but also ductile, and significantly improves the corrosion and wear behavior. The aim of this study is to understand the corrosion behavior of 3D-printed AlSi10Mg alloy and to improve its corrosion resistance. For this reason, the properties of CERANOD®—PEO coating on an AlSi10Mg alloy produced by SLM were investigated on different AM surfaces, i.e., as-built, polished and stress relieved specimens. The corrosion performance of these surfaces was analyzed using electrochemical impedance spectroscopy (EIS), potentiodynamic polarization, and long-term immersion tests. Moreover, the microstructure and morphology of the resulting coatings were characterized by SEM/EDS, taking into account the corrosive attacks. The results exhibited a high amount of localized corrosion in the case of the uncoated specimens, while the PEO process conducted on the aluminum AM surfaces led to enclosed homogeneous coatings by protecting the material’s pores, which are typically observed in AM process. Thereby, high corrosion protection could be achieved using PEO surfaces, suggesting that this technology is a promising candidate for unleashing the full potential of 3D light metal printing.

Evolution of Additive Manufacturing in Civil Infrastructure Systems: A Ten-Year Review

As human beings, we have a moral responsibility to act in a manner that takes the wellbeing of humans and Earth into consideration. When building, we must consider two things: the health of the workforce associated with construction and the state of the planet after building. Many engineers in the past have made groundbreaking achievements to revolutionize the civil infrastructure systems (CIS) industry. However, additive manufacturing (AM) has yet to be significantly recognized throughout the CIS industry. In this review, the use of all fundamental materials utilized by AM in CIS like concrete, metals, and polymers, are discussed. The objective of this study is to expand upon the technology of AM, specifically in CIS and to provide a review on the evolution of AM from 2011 to 2021. The different AM techniques that are utilized to construct said structures are also included. The review study suggests that AM can be useful in the CIS industry, as homes, bridges, and benches were manufactured with this technique. To enhance the reader’s visualization, pictures of the related built structures are also presented. It can be concluded that adopting AM techniques in the CIS industry can save material, speed up the construction process, and create a safer environment for the people that work in the CIS industry. Since the research on this subject is limited, further research on polymer printing along with metal printing is recommended.