scholarly journals Additive Manufacturing (AM) of Metallic Alloys

Crystals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 704
Author(s):  
Flaviana Calignano
Keyword(s):  
Additive Manufacturing ◽  
Metallic Alloys ◽  
Waste Material ◽  
Lead Times ◽  
Metal Additive Manufacturing ◽  
Lower Weight ◽  
Industrial Sectors ◽  
Potential Failure ◽  
Am Processes ◽  
Metal Additive

The introduction of metal additive manufacturing (AM) processes in industrial sectors, such as the aerospace, automotive, defense, jewelry, medical and tool-making fields, has led to a significant reduction in waste material and in the lead times of the components, innovative designs with higher strength, lower weight and fewer potential failure points from joining features [...]

Failures Related to Metal Additive Manufacturing

2021 ◽  
pp. 250-265
Author(s):  
Daniel P. Dennies ◽  
S. Lampman
Keyword(s):  
Quality Control ◽  
Additive Manufacturing ◽  
Powder Bed Fusion ◽  
Key Factors ◽  
Powder Bed ◽  
Metal Additive Manufacturing ◽  
Design Considerations ◽  
Directed Energy ◽  
Am Processes ◽  
Metal Additive

Abstract This article provides an overview of metal additive manufacturing (AM) processes and describes sources of failures in metal AM parts. It focuses on metal AM product failures and potential solutions related to design considerations, metallurgical characteristics, production considerations, and quality assurance. The emphasis is on the design and metallurgical aspects for the two main types of metal AM processes: powder-bed fusion (PBF) and directed-energy deposition (DED). The article also describes the processes involved in binder jet sintering, provides information on the design and fabrication sources of failure, addresses the key factors in production and quality control, and explains failure analysis of AM parts.

scholarly journals Beamless Metal Additive Manufacturing

Materials ◽  
2020 ◽  
Vol 13 (4) ◽  
pp. 922 ◽  
Author(s):  
Mohammad Vaezi ◽  
Philipp Drescher ◽  
Hermann Seitz
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Sintering ◽  
Metal Powders ◽  
Metal Additive Manufacturing ◽  
Wide Range ◽  
Anisotropic Mechanical Properties ◽  
High Production ◽  
High Production Cost ◽  
Am Processes ◽  
Metal Additive

The propensity to manufacture functional and geometrically sophisticated parts from a wide range of metals provides the metal additive manufacturing (AM) processes superior advantages over traditional methods. The field of metal AM is currently dominated by beam-based technologies such as selective laser sintering (SLM) or electron beam melting (EBM) which have some limitations such as high production cost, residual stress and anisotropic mechanical properties induced by melting of metal powders followed by rapid solidification. So, there exist a significant gap between industrial production requirements and the qualities offered by well-established beam-based AM technologies. Therefore, beamless metal AM techniques (known as non-beam metal AM) have gained increasing attention in recent years as they have been found to be able to fill the gap and bring new possibilities. There exist a number of beamless processes with distinctively various characteristics that are either under development or already available on the market. Since this is a very promising field and there is currently no high-quality review on this topic yet, this paper aims to review the key beamless processes and their latest developments.

scholarly journals Modelling of Microstructure Formation in Metal Additive Manufacturing: Recent Progress, Research Gaps and Perspectives

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1425
Author(s):  
Dayalan R. Gunasegaram ◽  
Ingo Steinbach
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Computational Modelling ◽  
Vital Role ◽  
Formation Mechanisms ◽  
Microstructure Formation ◽  
Metal Additive Manufacturing ◽  
The Status ◽  
Am Processes ◽  
Metal Additive

Microstructures encountered in the various metal additive manufacturing (AM) processes are unique because these form under rapid solidification conditions not frequently experienced elsewhere. Some of these highly nonequilibrium microstructures are subject to self-tempering or even forced to undergo recrystallisation when extra energy is supplied in the form of heat as adjacent layers are deposited. Further complexity arises from the fact that the same microstructure may be attained via more than one route—since many permutations and combinations available in terms of AM process parameters give rise to multiple phase transformation pathways. There are additional difficulties in obtaining insights into the underlying phenomena. For instance, the unstable, rapid and dynamic nature of the powder-based AM processes and the microscopic scale of the melt pool behaviour make it difficult to gather crucial information through in-situ observations of the process. Therefore, it is unsurprising that many of the mechanisms responsible for the final microstructures—including defects—found in AM parts are yet to be fully understood. Fortunately, however, computational modelling provides a means for recreating these processes in the virtual domain for testing theories—thereby discovering and rationalising the potential influences of various process parameters on microstructure formation mechanisms. In what is expected to be fertile ground for research and development for some time to come, modelling and experimental efforts that go hand in glove are likely to provide the fastest route to uncovering the unique and complex physical phenomena that determine metal AM microstructures. In this short Editorial, we summarise the status quo and identify research opportunities for modelling microstructures in AM. The vital role that will be played by machine learning (ML) models is also discussed.

A Comparative Study of Metal Additive Manufacturing Processes for Elevated Sustainability

2019 ◽  
Author(s):  
Wenbo Min ◽  
Sheng Yang ◽  
Ying Zhang ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Additive Manufacturing ◽  
Environmental Performance ◽  
Production Efficiency ◽  
Batch Size ◽  
Design Solution ◽  
Metal Additive Manufacturing ◽  
Direct Energy ◽  
Environmental Performance Assessment ◽  
Am Processes ◽  
Metal Additive

Abstract Metal additive manufacturing (AM) processes have gone through a compound growth over the past decade, and the technology is widely applied in industries like aerospace, automobile and bio-medical fields. There is an increasing need to understand and improve its sustainability given the high profile of existing environmental challenges. This paper aims at developing a precise comparative model for the three major metal AM processes (including Laser Powder Bed Fusion (LPBF), Electron Beam Melting (EBM), and Direct Energy Deposition (DED)) with respect to environmental performance assessment with a future goal of providing closed-loop feedbacks for design optimization with elevated sustainability. To improve the precision of previously reported models, new factors including embodied impacts of machine and recycled powder, operation patterns, system lifespan and batch size, are considered. A topologically optimized rocket bracket made of Ti6Al4V is used as an example to investigate the environmental performance of the three processes. The results showed that given the same design solution, the EBM had the lowest environmental impacts for low batch size, while the DED excelled at production efficiency.

scholarly journals Hybrid metal additive manufacturing: A state–of–the-art review

2021 ◽  
Vol 2 ◽  
pp. 100032
Author(s):  
J.P.M. Pragana ◽  
R.F.V. Sampaio ◽  
I.M.F. Bragança ◽  
C.M.A. Silva ◽  
P.A.F. Martins
Keyword(s):  
Additive Manufacturing ◽  
State Of The Art ◽  
Metal Additive Manufacturing ◽  
Metal Additive

scholarly journals Towards the industrialization of metal additive manufacturing

2021 ◽  
Vol 18 (3) ◽  
pp. 32-37
Author(s):  
Francesca Moglia ◽  
Antonio Raspa
Keyword(s):  
Additive Manufacturing ◽  
Metal Additive Manufacturing ◽  
Metal Additive
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