Academic literature on the topic 'AM metallic powder'
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Journal articles on the topic "AM metallic powder"
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Chike, Onuchukwu Godwin, Norhayati Binti Ahmad, and Uday Basheer Al-Naib. "Taxonomy on the production processes and characterization of powder metallurgy used in additive manufacturing process." Naukovyi Visnyk Natsionalnoho Hirnychoho Universytetu, no. 6 (December 25, 2022): 52–58. http://dx.doi.org/10.33271/nvngu/2022-6/052.
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Purpose. This article presents a concise and comprehensive review of the technologies that are typically used for manufacturing metal powders as well as the implications that particle features have on the properties of additive manufacturing (AM) techniques. Methodology. We surveyed various experiments that have taken place on the effects of the qualities of the powder and how to guarantee the dependability and reproducibility of the parts that are manufactured as well as ways of optimizing a powders performance. We classified the methods for producing metallic powders and highlighted the benefits, limitations, and image analysis of major production techniques. Findings. The usage of different approaches to metallic powder characterization for the analysis of the physical, mechanical, and chemical processes has contributed to major steps in powder optimization. The characterization of these powders is critical for ensuring adequate additive material dimensions and specifications and recording the properties of powders used in an AM and bridging the gap of comprehension concerning the end output in AM. Originality. This paper provides a thorough analysis of the efforts made in the powder characterization of AM components for the interpretation of the impact on the part materials qualities and characteristics. Metallic powder characterization has contributed to substantial progress toward powder optimization in the analysis of particle structures. Practical value. As the application of AM technology is moving away from the creation of prototypes and toward the production of finished products, it becomes important to understand the powder properties necessary to manufacture high-quality elements consistently.
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Cerejo, Fábio, Daniel Gatões, and M. T. Vieira. "Optimization of metallic powder filaments for additive manufacturing extrusion (MEX)." International Journal of Advanced Manufacturing Technology 115, no. 7-8 (May 25, 2021): 2449–64. http://dx.doi.org/10.1007/s00170-021-07043-0.
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AbstractAdditive manufacturing (AM) of metallic powder particles has been establishing itself as sustainable, whatever the technology selected. Material extrusion (MEX) integrates the ongoing effort to improve AM sustainability, in which low-cost equipment is associated with a decrease of powder waste during manufacturing. MEX has been gaining increasing interest for building 3D functional/structural metallic parts because it incorporates the consolidated knowledge from powder injection moulding/extrusion feedstocks into the AM scope—filament extrusion layer-by-layer. Moreover, MEX as an indirect process can overcome some of the technical limitations of direct AM processes (laser/electron-beam-based) regarding energy-matter interactions. The present study reveals an optimal methodology to produce MEX filament feedstocks (metallic powder, binder, and additives), having in mind to attain the highest metallic powder content. Nevertheless, the main challenges are also to achieve high extrudability and a suitable ratio between stiffness and flexibility. The metallic powder volume content (vol.%) in the feedstocks was evaluated by the critical powder volume concentration (CPVC). Subsequently, the rheology of the feedstocks was established by means of the mixing torque value, which is related to the filament extrudability performance.
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Grubbs, Jack, Bryer C. Sousa, and Danielle Cote. "Exploration of the Effects of Metallic Powder Handling and Storage Conditions on Flowability and Moisture Content for Additive Manufacturing Applications." Metals 12, no. 4 (March 31, 2022): 603. http://dx.doi.org/10.3390/met12040603.
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Metal powder-based additive manufacturing (AM) relies on consistently successful processing of feedstock powder, necessitating through-process predictability in powder properties and behavior. However, routine powder handling and storage may degrade powder performance by influencing flowability and moisture content through exposure to ambient conditions. Therefore, this study aimed to evaluate the effects of repeated environmental exposure on the flowability and moisture content of Al 5056 and Ta powders for AM applications. Using Carney Funnel flow tests, thermogravimetric analysis, and particle size/shape analysis, powder characterization helped elucidate powder property and behavioral changes with exposure. Results indicated inconsistent flowability and moisture content changes for both material types when exposure conditions were altered. Correlational statistics highlighted the most influential particle characteristics on powder behavior after exposure; particle morphology was most impactful for the semi-spherical Al 5056, whereas moisture content and particle size were most significant for the angular Ta. While exposure to laboratory conditions minimally changed powder performance in this study, caution is advised when handling and storing powders in more “extreme” environments. Powder users are urged to implement quality controls alongside powder characterization to pinpoint how specific powders should be treated, handled, and stored in a given environment for successful processing in AM.
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Grzelak, Krzysztof, Marcin Bielecki, Janusz Kluczyński, Ireneusz Szachogłuchowicz, Lucjan Śnieżek, Janusz Torzewski, Jakub Łuszczek, et al. "A Comparative Study on Laser Powder Bed Fusion of Differently Atomized 316L Stainless Steel." Materials 15, no. 14 (July 15, 2022): 4938. http://dx.doi.org/10.3390/ma15144938.
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The significant growth of Additive Manufacturing (AM), visible over the last ten years, has driven an increase in demand for small gradation metallic powders of a size lower than 100 µm. Until now, most affordable powders for AM have been produced using gas atomization. Recently, a new, alternative method of powder production based on ultrasonic atomization with melting by electric arc has appeared. This paper summarizes the preliminary research results of AM samples made of two AISI 316L steel powder batches, one of which was obtained during Ultrasonic Atomization (UA) and the other during Plasma Arc Gas Atomization (PAGA). The comparison starts from powder particle statistical distribution, chemical composition analysis, density, and flowability measurements. After powder analysis, test samples were produced using AM to observe the differences in microstructure, porosity, and hardness. Finally, the test campaign covered an analysis of mechanical properties, including tensile testing with Digital Image Correlation (DIC) and Charpy’s impact tests. A comparative study of parts made of ultrasonic and gas atomization powders confirms the likelihood that both methods can deliver material of similar properties.
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Tateno, Toshitake, Akira Kakuta, Hayate Ogo, and Takaya Kimoto. "Ultrasonic Vibration-Assisted Extrusion of Metal Powder Suspension for Additive Manufacturing." International Journal of Automation Technology 12, no. 5 (September 5, 2018): 775–83. http://dx.doi.org/10.20965/ijat.2018.p0775.
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Additive manufacturing (AM) using metal materials can be used to manufacture metal parts with complex shapes that are difficult to manufacture with subtractive processing. Recently, numerous commercial AM machines for metallic materials have been developed. The primary types of AM using metallic materials are powder bed fusion or direct energy deposition. Other types using metallic materials have not been adequately studied. In this study, the use of the material extrusion (ME) type of AM is investigated. The aim is to use metallic materials not only for fabricating metal parts but also for adding various properties to base materials, e.g., electric conductivity, thermal conductivity, weight, strength, and color of plastics. ME is appropriate for use with various materials by mixing different types of filler. However, there is a problem in that the high density of metal fillers generates unstable extrusion. Therefore, ultrasonic vibration was used for assisting extrusion. A prototype system was developed using an extrusion nozzle vibrated by an ultrasonic homogenizer. The experimental results showed that the ultrasonic vibration allows materials to be extruded smoothly. Three dimensional (3D) shapes could be built by multi-layer deposition with a thixotropic polymer containing a highly concentrated steel powder. As one application, a 3D-shaped object was fabricated as a sintered object. After the vibration effect in the extrusion process of steel powder and clay was confirmed, a 3D object built by the proposed method was sintered through a baking process.
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Koptyug, Andrey, Mikael Bäckström, Carlos Alberto Botero Vega, Vladimir Popov, and Ekaterina Chudinova. "Developing New Materials for Electron Beam Melting: Experiences and Challenges." Materials Science Forum 941 (December 2018): 2190–95. http://dx.doi.org/10.4028/www.scientific.net/msf.941.2190.
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Lack of industrially available materials for additive manufacturing (AM) of metallic materials along with the promises of materials with improved or unique properties provides a strong drive for developing new process/material combinations. As powder bed technologies for metallic materials are relatively new to the market, and to some extent are only maturing, developers of new process/material combinations have certain challenges to overcome. Firstly, basic knowledge on the behavior of materials (even those well established for other applications) under extreme conditions of melting/solidification with beam-based AM methods is far from being adequate. Secondly, manufacturing of the equipment is up to date driven by industrial application, thus optimization of the AM machines for small test batches of powders is still belongs to research and development projects. Also, majority of the powder manufacturers are primarily driven by the market development, and even they are well aware of the demands imposed by the powder bed AM machines, availability of small test batches of adequate powders may be problematic or at least quite costly for the R&D oriented users. Present paper describes the experiences in developing new materials for EBM A2 machine by Arcam EBM, modified for operating with powder batches of 100-200 ml and less. In particular it discusses achievements and challenges of working with powders from different materials with specifications far beyond the range suggested by machine manufacturer. Also it discusses the possibility of using blended rather than pre-alloyed powders for achieving both composite-like and alloyed materials in the same part by steering electron beam energy deposition strategy.
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Santos, Cyril, Daniel Gatões, Fábio Cerejo, and Maria Teresa Vieira. "Influence of Metallic Powder Characteristics on Extruded Feedstock Performance for Indirect Additive Manufacturing." Materials 14, no. 23 (November 24, 2021): 7136. http://dx.doi.org/10.3390/ma14237136.
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Material extrusion (MEX) of metallic powder-based filaments has shown great potential as an additive manufacturing (AM) technology. MEX provides an easy solution as an alternative to direct additive manufacturing technologies (e.g., Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition) for problematic metallic powders such as copper, essential due to its reflectivity and thermal conductivity. MEX, an indirect AM technology, consists of five steps—optimisation of mixing of metal powder, binder, and additives (feedstock); filament production; shaping from strands; debinding; sintering. The great challenge in MEX is, undoubtedly, filament manufacturing for optimal green density, and consequently the best sintered properties. The filament, to be extrudable, must accomplish at optimal powder volume concentration (CPVC) with good rheological performance, flexibility, and stiffness. In this study, a feedstock composition (similar binder, additives, and CPVC; 61 vol. %) of copper powder with three different particle powder characteristics was selected in order to highlight their role in the final product. The quality of the filaments, strands, and 3D objects was analysed by micro-CT, highlighting the influence of the different powder characteristics on the homogeneity and defects of the greens; sintered quality was also analysed regarding microstructure and hardness. The filament based on particles powder with D50 close to 11 µm, and straight distribution of particles size showed the best homogeneity and the lowest defects.
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Katz-Demyanetz, Alexander, Vladimir V. Popov, Aleksey Kovalevsky, Daniel Safranchik, and Andrey Koptyug. "Powder-bed additive manufacturing for aerospace application: Techniques, metallic and metal/ceramic composite materials and trends." Manufacturing Review 6 (2019): 5. http://dx.doi.org/10.1051/mfreview/2019003.
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The current paper is devoted to classification of powder-bed additive manufacturing (PB-AM) techniques and description of specific features, advantages and limitation of different PB-AM techniques in aerospace applications. The common principle of “powder-bed” means that the used feedstock material is a powder, which forms “bed-like” platform of homogeneous layer that is fused according to cross-section of the manufactured object. After that, a new powder layer is distributed with the same thickness and the “printing” process continues. This approach is used in selective laser sintering/melting process, electron beam melting, and binder jetting printing. Additionally, relevant issues related to powder raw materials (metals, ceramics, multi-material composites, etc.) and their impact on the properties of as-manufactured components are discussed. Special attention is paid to discussion on additive manufacturing (AM) of aerospace critical parts made of Titanium alloys, Nickel-based superalloys, metal matrix composites (MMCs), ceramic matrix composites (CMCs) and high entropy alloys. Additional discussion is related to the quality control of the PB-AM materials, and to the prospects of new approaches in material development for PB-AM aiming at aerospace applications.
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Liu, Jingfu, Behrooz Jalalahmadi, Y. B. Guo, Michael P. Sealy, and Nathan Bolander. "A review of computational modeling in powder-based additive manufacturing for metallic part qualification." Rapid Prototyping Journal 24, no. 8 (November 12, 2018): 1245–64. http://dx.doi.org/10.1108/rpj-04-2017-0058.
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PurposeAdditive manufacturing (AM) is revolutionizing the manufacturing industry due to several advantages and capabilities, including use of rapid prototyping, fabrication of complex geometries, reduction of product development cycles and minimization of material waste. As metal AM becomes increasingly popular for aerospace and defense original equipment manufacturers (OEMs), a major barrier that remains is rapid qualification of components. Several potential defects (such as porosity, residual stress and microstructural inhomogeneity) occur during layer-by-layer processing. Current methods to qualify AM parts heavily rely on experimental testing, which is economically inefficient and technically insufficient to comprehensively evaluate components. Approaches for high fidelity qualification of AM parts are necessary.Design/methodology/approachThis review summarizes the existing powder-based fusion computational models and their feasibility in AM processes through discrete aspects, including process and microstructure modeling.FindingsCurrent progresses and challenges in high fidelity modeling of AM processes are presented.Originality/valuePotential opportunities are discussed toward high-level assurance of AM component quality through a comprehensive computational tool.
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Ladani, Leila, and Maryam Sadeghilaridjani. "Review of Powder Bed Fusion Additive Manufacturing for Metals." Metals 11, no. 9 (September 1, 2021): 1391. http://dx.doi.org/10.3390/met11091391.
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Additive manufacturing (AM) as a disruptive technology has received much attention in recent years. In practice, however, much effort is focused on the AM of polymers. It is comparatively more expensive and more challenging to additively manufacture metallic parts due to their high temperature, the cost of producing powders, and capital outlays for metal additive manufacturing equipment. The main technology currently used by numerous companies in the aerospace and biomedical sectors to fabricate metallic parts is powder bed technology, in which either electron or laser beams are used to melt and fuse the powder particles line by line to make a three-dimensional part. Since this technology is new and also sought by manufacturers, many scientific questions have arisen that need to be answered. This manuscript gives an introduction to the technology and common materials and applications. Furthermore, the microstructure and quality of parts made using powder bed technology for several materials that are commonly fabricated using this technology are reviewed and the effects of several process parameters investigated in the literature are examined. New advances in fabricating highly conductive metals such as copper and aluminum are discussed and potential for future improvements is explored.
Dissertations / Theses on the topic "AM metallic powder"
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Sevastopolev, Ruslan. "Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component." Thesis, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-50949.
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Additive manufacturing can bring several advantages in tooling applications especially hot working tooling as high pressure die casting. Printing of conformal cooling channels can lead to improved cooling and faster solidification, which, in turn, can possibly result in better quality of the cast part. However, few studies on advantages of additive manufactured tools in high pressure die casting are published.The aim of this study was to investigate and quantify the effect of conformal cooling on microstructure and mechanical properties of high pressure die cast aluminum alloy. Two tools each consisting of two die inserts were produced with and without conformal channels using additive manufacturing. Both tools were used in die casting of aluminum alloy. Aluminum specimens were then characterized microstructurally in light optical microscope for secondary arm spacing measurements and subjected to tensile and hardness testing. Cooling behavior of different inserts was studied with a thermal camera and by monitoring the temperature change of cooling oil during casting. Surface roughness of die inserts was measured with profilometer before and after casting.Thermal imaging of temperature as a function of time and temperature change of oil during casting cycle indicated that conformal insert had faster cooling and lower temperature compared to conventional insert. However, thermal imaging of temperature after each shot in a certain point of time showed higher maximum and minimum temperature on conformal die surface but no significant difference in normalized temperature gradient compared to the conventional insert.The average secondary dendrite arm spacing values were fairly similar for samples from conventional and conformal inserts, while more specimens from conventional insert demonstrated coarser structure. Slower cooling in conventional insert could result in the coarser secondary dendrite arm spacing.Tensile strength and hardness testing revealed no significant difference in mechanical properties of the specimens cast in conventional and conformal die inserts. However, reduced deviations in hardness was observed for samples cast with conformal insert. This is in agreement with secondary dendrite arm spacing measurements indicating improved cooling with conformal insert.Surface roughness measurement showed small wear of the inserts. More castings are needed to observe a possible difference in wear between the conventional and conformal inserts.Small observed differences in cooling rate and secondary arm spacing did not result in evident difference in mechanical properties of the aluminum alloy but the variation in properties were reduced for samples cast with conformal cooling. Future work may include more accurate measurement of cooling behavior with a thermocouple printed into the die insert, casting of thicker specimen for porosity evaluation and fatigue testing and longer casting series to evaluate the influence of conformal cooling on tool wear.
Book chapters on the topic "AM metallic powder"
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Joseph, Jithin. "Direct Laser Fabrication of Compositionally Complex Materials." In Advances in Civil and Industrial Engineering, 147–63. IGI Global, 2020. http://dx.doi.org/10.4018/978-1-7998-4054-1.ch008.
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Additive manufacturing (AM) opens up the possibility of a direct build-up of components with sophisticated internal features or overhangs that are difficult to manufacture by a single conventional method. As a cost-efficient, tool-free, and digital approach to manufacturing components with complex geometries, AM of metals offers many critical benefits to various sectors such as aerospace, medical, automotive, and energy compared to conventional manufacturing processes. Direct laser fabrication (DLF) uses pre-alloyed powder mix or in-situ alloying of the elemental powders for metal additive manufacturing with excellent chemical homogeneity. It, therefore, shows great promise to enable the production of complex engineering components. This technique allows the highest build rates of the AM techniques with no restrictions on deposit size/shape and the fabrication of graded and hybrid materials by simultaneously feeding different filler materials. The advantages and disadvantages of DLF on the fabrication of compositionally complex metallic alloys are discussed in the chapter.
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Ury, Nicholas, Samad Firdosy, and Vilupanur Ravi. "Additive Manufacturing of Stainless Steel Biomedical Devices." In Additive Manufacturing in Biomedical Applications, 164–75. ASM International, 2022. http://dx.doi.org/10.31399/asm.hb.v23a.a0006888.
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Abstract Metallic alloys that are typically used for medical purposes include stainless steels, Ti-6Al-4V, and Co-Cr-Mo. This article discusses the relative merits of each of these alloys. The utilization of stainless steels in the biomedical industry, especially in relation to the additive manufacturing (AM) process, is the main focus of this article. The characteristics of various stainless steels are described subsequently, and the categories that are of relevance to the biomedical industry are identified. The types of stainless steels covered are austenitic, ferritic, martensitic, duplex, and precipitation-hardened stainless steels. The article discusses the potential benefits of AM for biomedical devices. It describes the types of AM processes for stainless steels, namely binder jet, directed-energy deposition, and laser powder-bed fusion. The article reviews the AM of austenitic, martensitic, and PH stainless steels for biomedical applications. In addition, the challenges and obstacles to the clinical use of AM parts are covered.
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Bandyopadhyay, Amit, Jose D. Avila, Indranath Mitra, and Susmita Bose. "Additive Manufacturing of Cobalt-Chromium Alloy Biomedical Devices." In Additive Manufacturing in Biomedical Applications, 176–91. ASM International, 2022. http://dx.doi.org/10.31399/asm.hb.v23a.a0006889.
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Abstract This article discusses some of the additive manufacturing (AM) based fabrication of alloys and their respective mechanical, electrochemical, and in vivo performance. Firstly, it briefly discusses the three AM techniques that are most commonly used in the fabrication of metallic biomedical-based devices: binder jetting, powder-bed fusion, and directed-energy deposition. The article then characterizes the electrochemical properties of additive-manufactured/processed cobalt-chromium alloys. This is followed by sections providing an evaluation of the biological response to CoCr alloys in terms of the material and 3D printing fabrication. Discussion on the biological response as a function of direct cellular activity on the surface of CoCr alloys in static conditions (in vitro), in dynamic physiological conditions (in vivo), and in computer-simulated conditions (in silico) are further discussed in detail. Finally, the article provides information on the qualification and certification of AM-processed medical devices.
Conference papers on the topic "AM metallic powder"
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Greco, Sebastian, Kevin Gutzeit, Hendrik Hotz, Marc Schmidt, Marco Zimmermann, Benjamin Kirsch, and Jan C. Aurich. "Influence of Machine Type and Powder Batch During Laser-Based Powder Bed Fusion (L-PBF) of AISI 316L." In ASME 2021 16th International Manufacturing Science and Engineering Conference. American Society of Mechanical Engineers, 2021. http://dx.doi.org/10.1115/msec2021-60448.
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Abstract The use of additive manufacturing (AM) in industrial applications is steadily increasing due to its near net shape production and high design-freedom. For metallic components, laser-based powder bed fusion (L-PBF) is currently one of the most widely used AM processes. During L-PBF, a component is manufactured layer by layer from a powdery raw material. The process is controlled by a multitude of parameters like the laser power, scanning speed and layer thickness, whose combination significantly influences the properties of the components. In this study, the influence of the L-PBF machine type and the influence of the powder batch are investigated by means of relative density, microhardness and microstructure of the components. For this purpose, three setups are defined, differing in the powder batch and machine type used. By comparing the process results of the additive manufacturing of different setups, the influence of the machine type and powder batch are determined. The considered material is stainless steel AISI 316L. The results revealed significant differences between all investigated properties of the additively manufactured components. Consequently, process parameter combinations cannot be transferred between different machine types and powder batches without verification of the component properties and, if necessary, special adaption of the process.
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Mun, Jiwon, Jaehyung Ju, and James Thurman. "Indirect Additive Manufacturing Based Casting (I AM Casting) of a Lattice Structure." In ASME 2014 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2014. http://dx.doi.org/10.1115/imece2014-38055.
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Direct-metal additive manufacturing (AM) processes such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM) methods are being used to fabricate complex metallic cellular structures with a laser or electron beam over a metal powder bed. Even though these processes have excellent capabilities to fabricate parts with cellular mesostructures, there exist several constraints in the processes and applications: limited selection of materials, high thermal stress by the high local energy source, poor surface finish, and anisotropic properties of parts caused by combined effects of one-dimensional (1D) energy based patterning mechanism, the deposition layer thickness, powder size, power and travel speed of laser or electron beam. In addition, manufacturing cost is still high with the Direct-metal AM processes. As an alternative for manufacturing metallic 3D cellular structures, which can overcome the disadvantages of direct-metal AM techniques, polymer AM methods may be combined with metal casting. We may call this “Indirect AM based Casting (I AM casting)”. The objective of this study is to explore the potential of I AM Casting associated with development of a novel manufacturing process — Indirect 3D Printing based centrifugal casting which is capable of producing multifunctional metallic cellular structures with internal cooling channels having a 2mm inner diameter and 0.5mm wall thickness. We characterize polymers by making expendable patterns with a polyjet type 3D printer; e.g., modulus, strength, melting and glass transition temperatures and thermal expansion coefficients. A transient flow and heat-transfer analysis of molten metal through 3D cellular network mold will be conducted. Solidification of molten metal through cellular mold during casting will be simulated with temperature dependent properties of molten metal and mold over a range of running temperatures. The volume of fluid (VOF) method will be implemented to simulate the solidification of molten metal together with a user defined function (UDF) of ANSYS/FLUENT. Finally, experimental validation will be conducted.
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Shen, Ninggang, and Kevin Chou. "Thermal Modeling of Electron Beam Additive Manufacturing Process: Powder Sintering Effects." In ASME 2012 International Manufacturing Science and Engineering Conference collocated with the 40th North American Manufacturing Research Conference and in participation with the International Conference on Tribology Materials and Processing. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/msec2012-7253.
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In recently developed Additive Manufacturing (AM) technologies, high-energy sources have been used to fabricate metallic parts, in a layer by layer fashion, by sintering and/or melting metal powders. In particular, Electron Beam Additive Manufacturing (EBAM) utilizes a high-energy electron beam to melt and fuse metal powders to build solid parts. EBAM is one of a few AM technologies capable of making full-density metallic parts and has dramatically extended their applications. Heat transport is the center of the process physics in EBAM, involving a high-intensity, localized moving heat source and rapid self-cooling, and is critically correlated to the part quality and process efficiency. In this study, a finite element model was developed to simulate the transient heat transfer in a part during EBAM subject to a moving heat source with a Gaussian volumetric distribution. The developed model was first examined against literature data. The model was then used to evaluate the powder porosity and the beam size effects on the high temperature penetration volume (melt pool size). The major findings include the following. (1) For the powder layer case, the melt pool size is larger with a higher maximum temperature compared to a solid layer, indicating the importance of considering powders for the model accuracy. (2) With the increase of the porosity, temperatures are higher in the melt pool and the molten pool sizes increase in the depth, but decrease along the beam moving direction. Furthermore, both the heating and cooling rates are higher for a lower porosity level. (3) A larger electron-beam diameter will reduce the maximum temperature in the melt pool and temperature gradients could be much smaller, giving a lower cooling rate. However, for the tested electron beam-power level, the beam diameter around 0.4 mm could be an adequate choice.
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Perisic, Milica, Yan Lu, and Albert Jones. "In-Process Data Integration for Laser Powder Bed Fusion Additive Manufacturing." In ASME 2022 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. American Society of Mechanical Engineers, 2022. http://dx.doi.org/10.1115/detc2022-91034.
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Abstract Additive manufacturing (AM) is a powerful technology that can create complex metallic parts and has the potential to improve the economic bottom line for various industries. However, due to process instabilities, and the resulting material defects that impact the part quality, AM still isn’t as widely used as it could be. To overcome this situation, it is crucial to develop an environment for easy, in-process monitoring and real-time control to detect process anomalies and predict part defects as quickly as possible. AM in-process monitoring measures various process variables and the sensors generate large volumes of structured or unstructured, 1D, 2D, and 3D data, some of which are acquired at very high frequencies. Integration of such data and their analysis are necessary for effective in-process monitoring and real-time control, but they are facing many challenges due to the characteristics of AM in-process data. This paper provides an overview of different in-process monitoring data sources and their connection methods and addresses the integration issues associated with acquiring and fusing the data for both on-fly control and offline analysis. The paper also presents a guideline to help high-speed data integration. This guideline can help users to decide the best data-integration configuration for a specific use case.
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Shen, Ninggang, and Kevin Chou. "Simulations of Thermo-Mechanical Characteristics in Electron Beam Additive Manufacturing." In ASME 2012 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/imece2012-88476.
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In the direct digital metal manufacturing, Electron Beam Additive Manufacturing (EBAM) has been used to fabricate sophisticated metallic parts, in a layer by layer fashion, by sintering and/or melting metal powders. In principle, EBAM utilizes a high-energy electron beam to melt and fuse metal powders to build solid parts with various materials, such as Ti-6Al-4V which is very difficult to fabricate using conventional processes. EBAM is one of a few Additive Manufacturing (AM) technologies capable of making full-density metallic parts and has drastically extended AM applications. The heat transfer analysis has been conducted in a simple case of a single-scan path with the effect of powder porosity investigated. In the actual EBAM process, the scan pattern is typically alternate raster. In this study, a coupled thermo-mechanical finite element model was developed to simulate the transient heat transfer, part residual stresses of alternate raster during the EBAM process subject to a moving heat source with a Gaussian volumetric distribution. The developed model was first examined against literature data. The coupled mechanical simulation is able to capture the evolution of the part residual stresses in EBAM.
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Hossain, Md Shahjahan, Hossein Taheri, Niraj Pudasaini, Alexander Reichenbach, and Bishal Silwal. "Ultrasonic Nondestructive Testing for In-Line Monitoring of Wire-Arc Additive Manufacturing (WAAM)." In ASME 2020 International Mechanical Engineering Congress and Exposition. American Society of Mechanical Engineers, 2020. http://dx.doi.org/10.1115/imece2020-23317.
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Abstract The applications for metal additive manufacturing (AM) are expanding. Powder-bed, powder-fed, and wire-fed AM are the different kinds of AM technologies based on the feeding material. Wire-Arc AM (WAAM) is a wire-fed technique that has the potential to fabricate large-scale three-dimensional objects. In WAAM, a metallic wire is continuously fed to the deposition location and is melted by an arc-welding power source. As the applications for WAAM expands, the quality assurance of the parts becomes a major concern. Nondestructive testing (NDT) of AM parts is necessary for quality assurance and inspection of these materials. The conventional method of inspection is to perform testing on the finished parts. There are several limitations encountered when using conventional methods of NDT for as-built AM parts due to surface conditions and complex structure. In-situ process monitoring based on the ultrasound technology is proposed for WAAM material inspection during the manufacturing process. Ultrasonic inline monitoring techniques have the advantages of providing valuable information about the process and parts quality. Ultrasonic technique was used to detect the process condition deviations from the normal. A fixture developed by the authors holds an ultrasonic sensor under the build platform and aligned with the center of the base plate. Ultrasonic signals were measured for different process conditions by varying the current and gas flow rate. Features (indicators) from the radio frequency (RF) signal were used to evaluate the difference in signal clusters to identify and classify different build conditions. Results show that the indicator values of the ultrasonic signals in the region of interest (ROI) changes with different process conditions and can be used to classify them.
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Woods, Matthew R., Nicholas A. Meisel, Timothy W. Simpson, and Corey J. Dickman. "Redesigning a Reaction Control Thruster for Metal-Based Additive Manufacturing: A Case Study in Design for Additive Manufacturing." In ASME 2016 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. American Society of Mechanical Engineers, 2016. http://dx.doi.org/10.1115/detc2016-59722.
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Prior research has shown that powder bed fusion additive manufacturing (AM) can be used to make functional, end-use components from powdered metallic alloys, such as Inconel® 718 super alloy. However, these end-use products are often based on designs developed for more traditional subtractive manufacturing processes without taking advantage of the unique design freedoms afforded by AM. In this paper, we present a case study involving the redesign of NASA’s existing “Pencil” thruster used for spacecraft attitude control. The initial “Pencil” thruster was designed for, and manufactured using, traditional subtractive methods. The main focus in this paper is to (a) review the Design for Additive Manufacturing (DfAM) concepts and considerations used in redesigning the thruster and (b) compare it with a parallel development effort redesigning the original thruster to be manufactured more effectively using subtractive processes. The results from this study show how developing end-use AM components using DfAM guidelines can significantly reduce manufacturing time and costs while introducing new and novel design geometries.
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San Marchi, Chris, Joshua D. Sugar, Thale R. Smith, and Dorian K. Balch. "Microstructure-Property Relationships in Powder Bed Fusion of Type 304L Austenitic Stainless Steel." In ASME 2018 Pressure Vessels and Piping Conference. American Society of Mechanical Engineers, 2018. http://dx.doi.org/10.1115/pvp2018-84901.
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Additive manufacturing (AM) includes a diverse suite of innovative manufacturing processes for producing near-net shape metallic components, typically from powder or wire. Reported mechanical properties of materials produced by these processes varies significantly and can usually be correlated with the relative porosity in the materials. In this study, relatively simple test components were manufactured from type 304L austenitic stainless steel by powder bed fusion (PBF). The quality of the components depends on a host of manufacturing parameters as well as the characteristics of the feedstock. In this study, the focus is the bulk material response. Tensile properties are reported for PBF type 304L produced in similar build geometries on two different machines with independent operators. Additionally, the effect of hydrogen on the tensile properties of the AM materials is evaluated. The goal of this study is to provide a benchmark for tensile properties of PBF 304L material in the context of wrought type 304L, and to make a preliminary assessment of the effects of hydrogen on tensile properties.
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Gong, Xibing, Ted Anderson, and Kevin Chou. "Review on Powder-Based Electron Beam Additive Manufacturing Technology." In ASME/ISCIE 2012 International Symposium on Flexible Automation. American Society of Mechanical Engineers, 2012. http://dx.doi.org/10.1115/isfa2012-7256.
Full textAbstract:
This paper presents a thorough literature review of the powder-based electron beam additive manufacturing (EBAM) technology. EBAM, a relatively new additive manufacturing (AM) process, can produce full-density metallic parts directly from the electronic data of the designed part geometry. EBAM has gained broad attentions from different industries such as aerospace and biomedical, with great potential in a variety of applications. The paper first introduces the general aspects of EBAM. The unique characteristics, advantages and challenges of EBAM are then presented. Moreover, the hub of this paper includes extensive discussions of microstructures, mechanical properties, geometric attributes, which impact the application ranges of EBAM parts, with focus on commonly used titanium alloys (in particular, Ti-6Al-4V). In the end, modeling work of the EBAM process is discussed as well.
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Ben Amor, Sabrine, Floriane Zongo, Borhen Louhichi, Vladimir Brailovski, and Antoine Tahan. "Classification of Dimensional Deviation in Additive Manufacturing LPBF Process for AlSi10Mg Alloy According to ISO 286 and ANSI B4.2." In ASME 2021 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. American Society of Mechanical Engineers, 2021. http://dx.doi.org/10.1115/detc2021-71683.
Full textAbstract:
Abstract Additive manufacturing (AM) processes are gaining popularity and are currently used in many research activities including the biomedical applications, the automotive industries and the aerospace. Laser powder bed fusion (LPBF) is an important AM process. Metallic LPBF process is experiencing significant growth, but one of the difficulties facing this growth is limited knowledge of its dimensional and geometrical performances, in addition to the inability to predict it. In this paper, we present the dimensional deviations of some LPBF-manufactured parts selected for this investigation. a uniform method was developed regarding relevant test specimens to examine dimensional deviations in order to derive dimensional tolerance values. The manufactured test specimens were measured to examine the process dimensional deviations behavior. These parts were manufactured from AlSi10Mg powder using an EOSINT M280 printer. The results show possible dimensional tolerance values that were classified from IT1 to IT11 according to the international standard ISO 286.
Reports on the topic "AM metallic powder"
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Slattery, Kevin. Unsettled Topics on Surface Finishing of Metallic Powder Bed Fusion Parts in the Mobility Industry. SAE International, January 2021. http://dx.doi.org/10.4271/epr2021001.
Full textAbstract:
Laser and electron-beam powder bed fusion (PBF) additive manufacturing (AM) technology has transitioned from prototypes and tooling to production components in demanding fields such as medicine and aerospace. Some of these components have geometries that can only be made using AM. Initial applications either take advantage of the relatively high surface roughness of metal PBF parts, or they are in fatigue, corrosion, or flow environments where surface roughness does not impose performance penalties. To move to the next levels of performance, the surfaces of laser and electron-beam PBF components will need to be smoother than the current as-printed surfaces. This will also have to be achieve on increasingly more complex geometries without significantly increasing the cost of the final component. Unsettled Topics on Surface Finishing of Metallic Powder Bed Fusion Parts in the Mobility Industry addresses the challenges and opportunities of this technology, and what remains to be agreed upon by the industry.