A Foil-Based Additive Manufacturing Technology for Metal Parts

2016 ◽  
Vol 139 (2) ◽  
Author(s):  
Chen Chen ◽  
Yiyu Shen ◽  
Hai-Lung Tsai
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Continuous Wave ◽  
Three Dimensional ◽  
Welding Process ◽  
Metal Powders ◽  
Metal Parts ◽  
Metal Foils ◽  
Raster Scan ◽  
Laser Spot Welding

In this paper, the method, system setup, and procedure of a new additive manufacturing (AM) technology for manufacturing three-dimensional (3D) metal parts are introduced. Instead of using metal powders as in most commercial AM technologies, the new method uses metal foils as feed stock. The procedure consists of two alternating processes: foil-welding by a high-power continuous-wave (CW) laser and foil-cutting by a Q-switched ultraviolet (UV) laser. The foil-welding process involves two subprocesses: laser spot welding and laser raster-scan welding. The reason for using two lasers is to achieve simultaneously the high-speed and high-precision manufacturing. The results on laser foil-welding and foil-cutting show that complete and strong welding bonds can be achieved with determined parameters, and that clean and no-burr/distortion cut of foil can be obtained. Several 3D AISI 1010 steel parts fabricated by the proposed AM technology are presented, and the microhardness and tensile strength of the as-fabricated parts are both significantly greater than those of the original foil.

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Three-Dimensional Modeling of Selective Laser Sintering of Two-Component Metal Powder Layers

2005 ◽  
Vol 128 (1) ◽  
pp. 299-306 ◽  
Author(s):  
Tiebing Chen ◽  
Yuwen Zhang
Keyword(s):  
Metal Powder ◽  
Continuous Wave ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Powder Layer ◽  
Metal Powders ◽  
Gaussian Laser Beam ◽  
Scanning Velocity ◽  
Three Dimensional Modeling

Laser sintering of a metal powder mixture that contains two kinds of metal powders with significantly different melting points under a moving Gaussian laser beam is investigated numerically. The continuous-wave laser-induced melting accompanied by shrinkage and resolidification of the metal powder layer are modeled using a temperature-transforming model. The liquid flow of the melted low-melting-point metal driven by capillary and gravity forces is also included in the physical model. The numerical results are validated by experimental results, and a detailed parametric study is performed. The effects of the moving heat source intensity, the scanning velocity, and the thickness of the powder layer on the sintering depth, the configuration of the heat affected zone, and the temperature distribution are discussed.

scholarly journals STUDIES ON MASK-LESS ELECTROCHEMICAL ADDITIVE MANUFACTURING

2021 ◽  
Author(s):  
Abhishek Bhardwaj
Keyword(s):  
Additive Manufacturing ◽  
High Power ◽  
Room Temperature ◽  
Three Dimensional ◽  
High Impact ◽  
Layer By Layer ◽  
Metal Parts ◽  
3D Cad ◽  
Cad Models

<div>Added substance Manufacturing (AM) of metallic designs is a warm cycle of layer by layer metal added substance fabricating measure produces parts straightforwardly from 3D CAD models. In this assembling interaction confined electrochemical affidavit joins with the added substance producing technique to make metal parts at room temperature. In this paper, the attainability of Mask-less Electrochemical Additive Manufacturing (ECAM), as a non-warm interaction is considered. Layer by layer testimony has been finished utilizing the electrochemical tips to make nickel microstructures. All the while beat wave qualities and their impacts on affidavit have been considered. </div><div>Confined electrodeposition (LED) was investigated as an AM the interaction with high power over measure boundaries and yield boundaries. The confinement of electrodeposition is completed by utilizing Ultra microelectrodes (UME) and low tossing power electrolytes. Variety in some cycle boundaries, for example, voltage and terminal hole are found to have a high impact on yield boundaries like thickness. The reproductions can anticipate the yield width of affidavit of analyses with a blunder of 8- 30%, so it can possibly apply as an added substance-producing strategy of complex three-dimensional (3D) parts on the microscale.</div>

scholarly journals Simultaneous Particle Tracking and Temperature Measurements during Additive Manufacturing using a High-speed Spectral Plenoptic Camera

2021 ◽  
Vol 1 (1) ◽  
Author(s):  
Dustin Kelly ◽  
Ralf Fischer ◽  
Ari Goldman ◽  
Sarah Morris ◽  
Bart Prorok ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Particle Tracking ◽  
Automotive Industry ◽  
High Speed ◽  
New Technology ◽  
Three Dimensional ◽  
Melt Pool ◽  
Plenoptic Camera ◽  
Metal Additive

In this work, a high-speed spectral plenoptic camera was used for three-dimensional (3D) simultaneous particle tracking and pyrometry measurements of hot spatter particles ejected during the metal additive manufacturing process. Additive manufacturing (AM) has an increasing role in the aerospace, energy, medical and automotive industry (DebRoy et al., 2018). While this new technology enables the production of highly advanced parts, research on the fundamental mechanisms governing the laser-matter interactions are an ongoing challenge because of the spatial and temporal resolution inherent to the AM process. One challenge is the characterization of spatter particles ejected from the melt pool, as these particles can be incorporated into the final part affecting the mechanical properties (Deng et al., 2020). One potential solution for simultaneously measuring velocity and temperature of the spatter particles is the spectral plenoptic camera.

Investigation of Image Characteristics of Plume and Spatters during High-Power Disk Laser Welding

2013 ◽  
Vol 709 ◽  
pp. 301-304 ◽  
Author(s):  
Gui Qian Liu ◽  
Xiang Dong Gao
Keyword(s):  
Laser Welding ◽  
High Power ◽  
Laser Power ◽  
High Speed ◽  
Continuous Wave ◽  
Welding Process ◽  
Metal Vapor ◽  
High Speed Photography ◽  
Monitoring And Control ◽  
Disk Laser

During high-power laser welding process, the workpiece produces metal vapor because of the laser irradiation. The characteristics of metal vapor are related to the quality and stability of welding and the utilization of the laser power. An approach of analyzing the characteristics of metal vapor was researched during high-power disk laser bead-on-plate welding of Type 304 austenitic stainless steel plates at a continuous wave laser power of 10 kW. A high-speed photography was used to capture metal vapor dynamic images. Metal vapor area, beam path, swing angle are calculated by image processing, which is the foundation for monitoring and control of welding quality in real time.

scholarly journals High-Speed Laser Cladding on Thin-Sheet-Substrates—Influence of Process Parameters on Clad Geometry and Dilution

Coatings ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 952
Author(s):  
Niklas Sommer ◽  
Florian Stredak ◽  
Stefan Böhm
Keyword(s):  
Laser Cladding ◽  
Process Parameters ◽  
High Speed ◽  
Continuous Wave ◽  
Thin Sheet ◽  
Production Method ◽  
Metal Powders ◽  
Influence Of Process Parameters ◽  
Target Values ◽  
Directed Energy

Laser-based Directed Energy Deposition (DED-LB) represents a production method of growing importance for cladding and additive manufacturing through the use of metal powders. Yet, most studies utilize substrate materials with thicknesses of multiple millimeters, for which laser cladding of thin-sheet substrates with thicknesses less than 1 mm have only been scarcely studied in the literature. Most studies cover the use of pulsed laser sources, since sheet distortion due to excess energy input is a key problem in laser cladding of thin-sheet substrates. Hence, the authors of the present investigation seek to expand the boundaries of cladding thin-sheet substrates through the use of a high-speed laser cladding approach which utilizes a continuous-wave, ytterbium fiber laser and traverse speeds of 90 mms−1 to clad stainless steel sheets with a thickness of 0.8mm. Furthermore, fundamental process–property relationships for the target values of clad width, clad height, and dilution depth are studied and thoroughly discussed. Additionally, process maps for the target values are established based on manifold experiments, and the significance of process parameters on target values is studied using analysis of variance. The results demonstrate that clad widths as high as 1413 μm and dilution depths as low as 144 μm can be obtained by high-speed laser cladding of thin-sheet substrates. Thus, pathways toward thin-sheet substrates with enhanced performance are opened.

scholarly journals Properties and anisotropy behaviour of a nickel base alloy material produced by robot-based wire and arc additive manufacturing

2020 ◽  
Vol 64 (11) ◽  
pp. 1921-1931
Author(s):  
Thomas Hassel ◽  
Torben Carstensen
Keyword(s):  
Additive Manufacturing ◽  
Anisotropic Material ◽  
High Performance ◽  
Base Alloy ◽  
Deformation Behaviour ◽  
Welding Process ◽  
Polished Surface ◽  
Metal Powders ◽  
Material Behaviour ◽  
Process Technology

Abstract In order to produce three-dimensional components from metals, a wide variety of processes exist. Laser processes combined with metal powders are frequently used and developed. Restrictive factors are the machine-related small workspace, the machinery costs and the material portfolio, which place the technology in the area of high-performance components. Wire and arc additive manufacturing (WAAM), as a robust and economical welding process technology in combination with robot applications, represents an option to become more size-independent and provides variability in the range of materials. This work shows results for the robot-based WAAM of structures made from nickel alloy 617. The main focus of the investigation was the determination of the mechanical properties in the as-welded state for which static strength tests, microhardness and metallographic studies were carried out. The anisotropic material behaviour in relation to the build direction (BD) was tested. The direction-dependent strength properties of single-track welded structures are presented with samples taken and tested at 0°, 45° and 90° to the BD. The deformation behaviour was investigated by micro-tensile tests in a scanning electron microscope, whereby the formation of sliding steps on the polished surface under tensile stress was studied. The anisotropic behaviour of the WAAM structures is discussed under consideration of the microstructure and with regard to the grain size development and phase formation. The results indicate an anisotropic material behaviour in the as-welded state based of the crystallographic orientation of the material.

scholarly journals A novel microscale selective laser sintering (μ-SLS) process for the fabrication of microelectronic parts

2019 ◽  
Vol 5 (1) ◽  
Author(s):  
Nilabh K. Roy ◽  
Dipankar Behera ◽  
Obehi G. Dibua ◽  
Chee S. Foong ◽  
Michael A. Cullinan
Keyword(s):  
Additive Manufacturing ◽  
New Technology ◽  
Selective Laser Sintering ◽  
Three Dimensional ◽  
Laser Sintering ◽  
Metal Nanoparticle ◽  
Metal Parts ◽  
Nanoparticle Layer ◽  
Slot Die ◽  
Commercial Applications

AbstractOne of the biggest challenges in microscale additive manufacturing is the production of three-dimensional, microscale metal parts with a high enough throughput to be relevant for commercial applications. This paper presents a new microscale additive manufacturing process called microscale selective laser sintering (μ-SLS) that can produce true 3D metal parts with sub-5 μm resolution and a throughput of greater than 60 mm3/hour. In μ-SLS, a layer of metal nanoparticle ink is first coated onto a substrate using a slot die coating system. The ink is then dried to produce a uniform nanoparticle layer. Next, the substrate is precisely positioned under an optical subsystem using a set of coarse and fine nanopositioning stages. In the optical subsystem, laser light that has been patterned using a digital micromirror array is used to heat and sinter the nanoparticles into the desired patterns. This set of steps is then repeated to build up each layer of the 3D part in the μ-SLS system. Overall, this new technology offers the potential to overcome many of the current limitations in microscale additive manufacturing of metals and become an important process in microelectronics packaging applications.

Ultrasonic Vibration-Assisted Extrusion of Metal Powder Suspension for Additive Manufacturing

2018 ◽  
Vol 12 (5) ◽  
pp. 775-783 ◽  
Author(s):  
Toshitake Tateno ◽  
Akira Kakuta ◽  
Hayate Ogo ◽  
Takaya Kimoto ◽  
◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Ultrasonic Vibration ◽  
Three Dimensional ◽  
Steel Powder ◽  
Extrusion Process ◽  
Prototype System ◽  
Metallic Materials ◽  
Metal Parts ◽  
Vibration Effect ◽  
Direct Energy

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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