scholarly journals Metal Additive Manufacturing for Satellites and Rockets

2021 ◽  
Vol 11 (24) ◽  
pp. 12036
Author(s):  
Tomasz Blachowicz ◽  
Guido Ehrmann ◽  
Andrea Ehrmann
Keyword(s):  
Additive Manufacturing ◽  
Three Dimensional ◽  
Heat Pipes ◽  
Space Applications ◽  
Metal Additive Manufacturing ◽  
Magnetic Shields ◽  
Custom Made ◽  
Manufacturing Technologies ◽  
Harsh Conditions ◽  
Metal Additive

The emerging technology of 3D printing can not only be used for rapid prototyping, but will also play an important role in space exploration. Additive manufactured parts can be used in diverse space applications, such as magnetic shields, heat pipes, thrusters, etc. Three-dimensional printed parts offer reduced mass, high possible complexity, and fast printability of custom-made objects. On the other hand, materials which are not excessively damaged by the harsh conditions in space and are also printable by available technologies are not abundantly available. This review gives an overview of recent metal additive manufacturing technologies and their possible applications in space, with a focus on satellites and rockets, highlighting already applied technologies and materials and gives an outlook on possible future applications and challenges.

scholarly journals Material Reuse in Laser Powder Bed Fusion: Side Effects of the Laser—Metal Powder Interaction

Metals ◽  
2020 ◽  
Vol 10 (3) ◽  
pp. 341 ◽  
Author(s):  
Eleonora Santecchia ◽  
Stefano Spigarelli ◽  
Marcello Cabibbo
Keyword(s):  
Additive Manufacturing ◽  
Side Effects ◽  
Metal Powder ◽  
Three Dimensional ◽  
High Energy ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Metal Additive Manufacturing ◽  
Metal Additive

Metal additive manufacturing is changing the way in which engineers and designers model the production of three-dimensional (3D) objects, with rapid growth seen in recent years. Laser powder bed fusion (LPBF) is the most used metal additive manufacturing technique, and it is based on the efficient interaction between a high-energy laser and a metal powder feedstock. To make LPBF more cost-efficient and environmentally friendly, it is of paramount importance to recycle (reuse) the unfused powder from a build job. However, since the laser–powder interaction involves complex physics phenomena and generates by-products which might affect the integrity of the feedstock and the final build part, a better understanding of the overall process should be attained. The present review paper is focused on the clarification of the interaction between laser and metal powder, with a strong focus on its side effects.

scholarly journals Smart Build-Plate for Metal Additive Manufacturing Processes

Sensors ◽  
2020 ◽  
Vol 20 (2) ◽  
pp. 360 ◽  
Author(s):  
Adam Hehr ◽  
Mark Norfolk ◽  
Dan Kominsky ◽  
Andrew Boulanger ◽  
Matthew Davis ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Fiber Optic ◽  
Defect Formation ◽  
High Definition ◽  
Powder Bed ◽  
Metal Additive Manufacturing ◽  
Ultrasonic Additive Manufacturing ◽  
Fiber Optic Sensing ◽  
Manufacturing Technologies ◽  
Metal Additive

This paper discusses the development, processing steps, and evaluation of a smart build-plate or baseplate tool for metal additive manufacturing technologies. This tool uses an embedded high-definition fiber optic sensing fiber to measure strain states from temperature and residual stress within the build-plate for monitoring purposes. Monitoring entails quality tracking for consistency along with identifying defect formation and growth, i.e., delamination or crack events near the build-plate surface. An aluminum alloy 6061 build-plate was manufactured using ultrasonic additive manufacturing due to the process’ low formation temperature and capability of embedding fiber optic sensing fiber without damage. Laser-powder bed fusion (L-PBF) was then used to print problematic geometries onto the build-plate using AlSi10Mg for evaluation purposes. The tool identified heat generation, delamination onset, and delamination growth of the printed L-PBF parts.

scholarly journals 3D Puzzle in Cube Pattern for Anisotropic/Isotropic Mechanical Control of Structure Fabricated by Metal Additive Manufacturing

Crystals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 959
Author(s):  
Naoko Ikeo ◽  
Hidetsugu Fukuda ◽  
Aira Matsugaki ◽  
Toru Inoue ◽  
Ai Serizawa ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Mechanical Performance ◽  
Functional Performance ◽  
Three Dimensional ◽  
Material Design ◽  
Metal Additive Manufacturing ◽  
Anisotropic Mechanical Properties ◽  
Innovative Material ◽  
Living Tissues ◽  
Metal Additive

Metal additive manufacturing is a powerful tool for providing the desired functional performance through a three-dimensional (3D) structural design. Among the material functions, anisotropic mechanical properties are indispensable for enabling the capabilities of structural materials for living tissues. For biomedical materials to replace bone function, it is necessary to provide an anisotropic mechanical property that mimics that of bones. For desired control of the mechanical performance of the materials, we propose a novel 3D puzzle structure with cube-shaped parts comprising 27 (3 × 3 × 3) unit compartments. We designed and fabricated a Co–Cr–Mo composite structure through spatial control of the positional arrangement of powder/solid parts using the laser powder bed fusion (L-PBF) method. The mechanical function of the fabricated structure can be predicted using the rule of mixtures based on the arrangement pattern of each part. The solid parts in the cubic structure were obtained by melting and solidifying the metal powder with a laser, while the powder parts were obtained through the remaining nonmelted powders inside the structure. This is the first report to achieve an innovative material design that can provide an anisotropic Young’s modulus by arranging the powder and solid parts using additive manufacturing technology.

scholarly journals A Comparative Study between Polymer and Metal Additive Manufacturing Approaches in Investigating Stiffened Hexagonal Cells

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 883
Author(s):  
Othman Laban ◽  
Elsadig Mahdi ◽  
Samahat Samim ◽  
John-John Cabibihan
Keyword(s):  
Additive Manufacturing ◽  
Failure Modes ◽  
Fused Deposition Modelling ◽  
Complex Structures ◽  
Metal Additive Manufacturing ◽  
Fused Deposition ◽  
Base Materials ◽  
Load Carrying ◽  
Manufacturing Technologies ◽  
Metal Additive

Recent polymer and metal additive manufacturing technologies were proven capable of building complex structures with high accuracy. Although their final products differ significantly in terms of mechanical properties and building cost, many structural optimization studies were performed with either one without systematic justification. Therefore, this study investigated whether the Direct Metal Laser Sintering (DMLS) and Fused Deposition Modelling (FDM) methodologies can provide similar conclusions when performing geometrical manipulations for optimizing structural crashworthiness. Two identical sets of four shapes of stiffened hexagonal cells were built and crushed under quasi-static loading. The results were compared in terms of collapsing behavior, load-carrying performance, and energy-absorption capability. Although the observed failure modes were different since the base-materials differ, similar improvement trends in performance were observed between both fabrication approaches. Therefore, FDM was recommended as a fabrication method to optimize thin-walled cellular hexagonal parameters since it was 80% more time-efficient and 53.6% cheaper than the DMLS technique.

scholarly journals An Investigation of the Metal Additive Manufacturing Issues and Perspective for Solutions Approach

2021 ◽  
Author(s):  
Omar Ahmed Al-Shebeeb
Keyword(s):  
Additive Manufacturing ◽  
Product Quality ◽  
Complex Geometry ◽  
Three Dimensional ◽  
Design For Additive Manufacturing ◽  
Potential Approach ◽  
Metal Additive Manufacturing ◽  
Metallic Parts ◽  
Metal Additive

Metal Additive Manufacturing (MAM) is delivering a new revolution in producing three-dimensional parts from metal-based material. MAM can fabricate metallic parts with complex geometry. However, this type of Additive Manufacturing (AM) is also impacted by several issues, challenges, and defects, which influence product quality and process sustainability. In this chapter, a review has been made on the types of small to medium-sized metallic parts currently manufactured using the MAM method. Then, investigation was undertaken to analyze the defects, challenges, and issues inherent to the design for additive manufacturing, by using MAM method. MAM-related obstacles are discussed in depth in this chapter and these obstacles occur in all size of metal printed parts. The reasons and solutions presented by previous researchers of these obstacles are discussed as well. A potential approach based on the author’s knowledge and analysis for solving these issues and challenges is suggested in this chapter. Based on the author’s conclusion, the MAM is not limited by part size, material, or geometry. In order to validate the potential solutions developed by the author of this work, performing actual MAM process is required and a local visit to manufacturing factories are also important to visualize these challenges and issues.

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