Additive Manufacturing of Metal Structures at the Micrometer Scale

2017 ◽  
Vol 29 (17) ◽  
pp. 1604211 ◽  
Author(s):  
Luca Hirt ◽  
Alain Reiser ◽  
Ralph Spolenak ◽  
Tomaso Zambelli
Keyword(s):  
Additive Manufacturing ◽  
Metal Structures ◽  
Micrometer Scale

Bulk Nanocrystalline Permanent Magnets by Selective Laser Melting

2021 ◽  
Vol 58 (10) ◽  
pp. 630-643
Author(s):  
F. Trauter ◽  
J. Schanz ◽  
H. Riegel ◽  
T. Bernthaler ◽  
D. Goll ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Field Strength ◽  
Selective Laser Melting ◽  
Permanent Magnets ◽  
Maximum Energy ◽  
Laser Melting ◽  
Maximum Energy Product ◽  
Energy Product ◽  
Bulk Nanocrystalline ◽  
Micrometer Scale

Abstract Fe-Nd-B powders were processed by additive manufacturing using laboratory scale selective laser melting to produce bulk nanocrystalline permanent magnets. The manufacturing process was carried out in a specially developed process chamber under Ar atmosphere. This resulted in novel types of microstructures with micrometer scale clusters of nanocrystalline hard magnetic grains. Owing to this microstructure, a maximum coercive field strength (coercivity) μ0Hc of 1.16 T, a remanence Jr of 0.58 T, and a maximum energy product (BH)max of 62.3 kJ/mm3could, for example, be obtained for the composition Nd16.5-Pr1.5-Zr2.6-Ti2.5-Co2.2-Fe65.9-B8.8.

scholarly journals Investigating the Mechanics of Hybrid Metal Extrusion and Bonding Additive Manufacturing by FEA

Metals ◽  
2019 ◽  
Vol 9 (8) ◽  
pp. 811 ◽  
Author(s):  
Jørgen Blindheim ◽  
Torgeir Welo ◽  
Martin Steinert
Keyword(s):  
Additive Manufacturing ◽  
Material Flow ◽  
Deposition Process ◽  
Feed Speed ◽  
Element Analysis ◽  
Reduced Pressure ◽  
Metal Structures ◽  
Material Deposition ◽  
Flow Through ◽  
Metal Extrusion

Hybrid Metal Extrusion & Bonding Additive Manufacturing (HYB-AM) is a hybrid manufacturing technology for the deposition of layered metal structures. This new deposition process is a complex metal forming operation, yet there is significant lack of knowledge regarding the governing mechanisms. In this work, we have used finite element analysis (FEA) to study material flow in the extruder, as well as the conditions at the interfaces of the deposited extrudate and the substrate, aiming to identify and characterize the process parameters involved. Analysis of the material flow shows that the extrusion pressure is virtually independent of the deposition rate. Furthermore, from the simulations of the material deposition sequence, it is clearly visible how the contact pressure at the interface will drop below the bonding threshold if the feed speed is too high relative to the material flow through the die. The reduced pressure also leads to the formation of a ‘gas-pocket’ inside the die, thus further degrading the conditions for bonding. The analyses of the process have provided valuable insights for the further development and industrialization of the process.

Formation of Micrometer Scale Metal Structures on Glass by Selective Electroless Plating on Photopatterned Titanium and Copper Containing Films

Langmuir ◽  
2017 ◽  
Vol 33 (51) ◽  
pp. 14571-14579 ◽  
Author(s):  
Christopher E. J. Cordonier ◽  
Kyohei Okabe ◽  
Yoshio Horiuchi ◽  
Akimasa Nakamura ◽  
Kaoru Ishikawa ◽  
...  
Keyword(s):  
Electroless Plating ◽  
Metal Structures ◽  
Micrometer Scale

scholarly journals Stereo-photometric techniques for scanning micrometer scale

2015 ◽  
Vol 6 (13) ◽  
pp. 72 ◽  
Author(s):  
Rocio Cachero ◽  
Carlota Abello
Keyword(s):  
Additive Manufacturing ◽  
3D Printing ◽  
Great Accuracy ◽  
Manufacturing Methods ◽  
Micrometer Scale

This paper describes a new methodology based on the combination of photogrammetric and stereo-photometric techniques that allows creating virtual replicas reproducing the relief in micrometric scale, with a geometric resolution until 7 microns. The finest details of the texture obtained by photogrammetric methods are translated to the relief of the mesh to provide quality 3D printing by additive manufacturing methods. These results open new possibilities for virtual and physical reproduction of archeological items that need a great accuracy and geometric resolution.

scholarly journals Development of Monitoring Techniques for Laser Powder Bed Additive Manufacturing of Metal Structures (Progress Report)

2020 ◽  
Author(s):  
Luke Scime ◽  
William Halsey ◽  
James Haley ◽  
Alka Singh ◽  
Michael Sprayberry ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Progress Report ◽  
Powder Bed ◽  
Metal Structures ◽  
Monitoring Techniques

scholarly journals The Digital Twin and Optimization of Cast Metal Structures in Additive Manufacturing

2020 ◽  
pp. 56-65
Author(s):  
Volodymyr S. Doroshenko ◽  
◽  
Olena V. Tokova ◽  
Keyword(s):  
Additive Manufacturing ◽  
Technological Development ◽  
Engineering Science ◽  
Processing Industry ◽  
Metal Structures ◽  
Cast Metal ◽  
Production Processes ◽  
Technical Base ◽  
Advanced Development ◽  
Additive Methods

The actual task of engineering science should be to promote the technological development of the national economy, modernization of its material and technical base with the advanced development of the processing industry. One of the modern technological trends is the “digitalization” of production processes, the features of which on the examples of obtaining cast metal structures by additive methods will be considered in this article.

Use of Polymer Scaffolding and Electroplating to Create Porous Metal Structures

2019 ◽  
Vol 141 (3) ◽  
Author(s):  
Adam Mihalko ◽  
Jordan Felice ◽  
Allen Madura ◽  
Davide Piovesan
Keyword(s):  
Composite Material ◽  
Additive Manufacturing ◽  
Complex Shape ◽  
Porous Metal ◽  
Fabrication Method ◽  
Fabrication Technique ◽  
Metal Structures ◽  
Porosity And Permeability ◽  
Porous Composites ◽  
Metallic Artifacts

Additive manufacturing (AM) offers a fabrication process that provides numerous advantages when compared with traditional fabrication methods. Specifically, AM technology allows for the creation of porous media where porosity and permeability can be precisely controlled. When manufacturing metallic artifacts for biomedical use (e.g., bone implants), the investment in a laser sintering machine can be prohibitive for the budget-conscious enterprises limiting the study and use of this technology. Electroforming, electroplating, and electrotyping have been used for decades to replicate the complex shape of unique artifacts and can be viable techniques to create complex metallic shapes starting from a conductive mandrel. We investigated a fabrication technique that combines the stereolithographic additive manufacturing of a polymeric mandrel with electroforming, to obtain porous composites of polymers and metals. The fabrication method to electroform a porous artifact is presented, and an analytical model of the combined properties of the composite material is provided.

scholarly journals Diffraction-Based Residual Stress Characterization in Laser Additive Manufacturing of Metals

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1830
Author(s):  
Jakob Schröder ◽  
Alexander Evans ◽  
Tatiana Mishurova ◽  
Alexander Ulbricht ◽  
Maximilian Sprengel ◽  
...  
Keyword(s):  
Residual Stress ◽  
Additive Manufacturing ◽  
Interaction Model ◽  
Research Field ◽  
Laser Additive Manufacturing ◽  
Metal Structures ◽  
Grain Interaction ◽  
Future Demands ◽  
Non Destructive

Laser-based additive manufacturing methods allow the production of complex metal structures within a single manufacturing step. However, the localized heat input and the layer-wise manufacturing manner give rise to large thermal gradients. Therefore, large internal stress (IS) during the process (and consequently residual stress (RS) at the end of production) is generated within the parts. This IS or RS can either lead to distortion or cracking during fabrication or in-service part failure, respectively. With this in view, the knowledge on the magnitude and spatial distribution of RS is important to develop strategies for its mitigation. Specifically, diffraction-based methods allow the spatial resolved determination of RS in a non-destructive fashion. In this review, common diffraction-based methods to determine RS in laser-based additive manufactured parts are presented. In fact, the unique microstructures and textures associated to laser-based additive manufacturing processes pose metrological challenges. Based on the literature review, it is recommended to (a) use mechanically relaxed samples measured in several orientations as appropriate strain-free lattice spacing, instead of powder, (b) consider that an appropriate grain-interaction model to calculate diffraction-elastic constants is both material- and texture-dependent and may differ from the conventionally manufactured variant. Further metrological challenges are critically reviewed and future demands in this research field are discussed.

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