Technological Innovations in Metals Engineering (original) (raw)
Related papers
Advances in Metal Additive Manufacturing
Woodhead Publishing, 2022
Advances in Metal Additive Manufacturing explains fundamental information and the latest research on new technologies, including powder bed fusion, direct energy deposition using high energy beams, and hybrid additive and subtractive methods. This book introduces readers to the technology, provides everything needed to understand how the different stages work together, and inspires to think beyond traditional metal processing to capture new ideas in metal. Chapters offer an introduction on metal additive manufacturing, processes, and properties and standards and then present surveys on the most significant international advances in metal additive manufacturing. Throughout, the book presents a focus on the effect of important process parameters on the microstructure, mechanical properties and wear behavior of additively manufactured parts.
IRJET, 2023
Additive manufacturing has emerged as a game-changing technology in the manufacturing industry, particularly in the aerospace sector. Metal additive manufacturing, in particular, has garnered considerable attention due to its unique ability to produce complex geometries with high precision and accuracy. This review paper focuses to provide a comprehensive overview of the common metal additive manufacturing processes, their applications in the aerospace industry, and the challenges that lie ahead. The study begins with a brief introduction to metal additive manufacturing, followed by a detailed analysis of the most commonly used processes, such as laser bed melting, powder bed fusion, directed energy deposition, and binder jetting. Next, the paper explores the various aerospace applications of metal additive manufacturing, including engine components, structural parts, and tooling. Finally, the review concludes by discussing the current limitations and future challenges of metal additive manufacturing, such as the need for improved material properties, cost reduction, and standardisation. Overall, this paper provides valuable insights for researchers, practitioners, and policymakers interested in the potential of metal additive manufacturing in aerospace and beyond.
Applied Sciences
In recent years, Additive Manufacturing (AM), also called 3D printing, has been expanding into several industrial sectors due to the technology providing opportunities in terms of improved functionality, productivity, and competitiveness. While metal AM technologies have almost unlimited potential, and the range of applications has increased in recent years, industries have faced challenges in the adoption of these technologies and coping with a turbulent market. Despite the extensive work that has been completed on the properties of metal AM materials, there is still a need of a robust understanding of processes, challenges, application-specific needs, and considerations associated with these technologies. Therefore, the goal of this study is to present a comprehensive review of the most common metal AM technologies, an exploration of metal AM advancements, and industrial applications for the different AM technologies across various industry sectors. This study also outlines curren...
Metal additive manufacturing: Technology, metallurgy and modelling
Journal of Manufacturing Processes, 2020
This paper provides a comprehensive review of metal additive manufacturing, a rapidly evolving field with innovative technologies and processes. The purpose of this review paper is to provide a complete picture of the current research on metal AM and its capabilities. An overview of metal AM and the current processing methods are provided, along with a brief introduction to the complex physics behind the melt pool formation. Common metal AM characteristic defects are discussed as well as the current metals and alloys that are commercially available. Furthermore, process optimization techniques and computational modelling methods are reviewed. Lastly, various post-processing methods to improve surface roughness, mechanical properties and dimensional precision are discussed. Although the library for printable alloys is increasing, there is still a need for alloy development outside of the commercial setting. Furthermore, there is currently not a complete numerical model of the AM process which is mainly due to the computational costs. Although metal AM is still in its infancy, the frequency and significance of new developments are driving AM to mainstream adoption.
Additive manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire or sheets in a process that proceeds layer by layer. Many techniques (using many different names) have been developed to accomplish this via melting or solid-state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid-state precipitation, mechanical properties and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Only a few alloys have been developed for commercial production, but recent efforts are presented as a path for the ongoing development of new materials for AM processes.
2016
Metal-based Additive Manufacturing (MbAM) is an additive manufacturing process for the direct fabrication of prototypes, tools and fully functional parts. The MbAM equipment usually uses a high intensity laser beam that will completely melt the metal powder particles, according to a layer defined from a three-dimensional CAD model. There are several processes available, from different suppliers, and for this work the selected one was the Direct Metal Laser Sintering (DMLS), from EOS GmbH. DMLS is capable of producing high density parts, with mechanical properties similar to traditional manufacturing techniques and with cost control when complex geometry increases. DMLS can work with different materials, and in this cases it was used maraging steel (1.2709), an iron-nickel steel alloy with good mechanical properties, easily heat treatable using an age-hardening process which will enable superior hardness and strength. The experimental investigation involved the analysis of maraging steel powder, microstructure of produced parts, mechanical properties and dimensional analysis. The results of experimental evaluation demonstrated that after age-hardening parts achieved the hardness pre-defined requirements, they also present, at the same time, a very high density. With this dissertation it is intended to bring knowledge about MbAM to YAZAKI to support future steps and decisions. The first chapter, Literature Revision, starts by presenting additive manufacturing, defining it and showing the path taken. After this, it is presented all the different process approaches to MbAM, benefits and limitations. It ends with the analysis of the equipment used in this work, EOS M 290, and properties of maraging steel. The second chapter, Experimental Procedure, mentions all the methods used, from parts manufacturing to post-processing operations (trimming, age-hardening) and analysis carried out (like hardness, SEM/EDS evaluations, tensile tests, among others). The results are presented and analyzed in chapter three, and conclusions are presented in chapter four. The report finishes with Future Steps chapter.
A current state of metal additive manufacturing methods: A review
Alloys such as super alloys, Aluminium, titanium alloys are employed for metal additive manufacturing significantly. These alloys are used to make aircraft components, gas turbines and other structural areas. Additive manufacturing (AM), is also known as direct digital manufacturing methods, has improved the mechanical properties of additively manufactured metals. This paper overviews about various metal additive manufacturing methods on recent development and impact of process factors on mechanical behaviour, microstructures, formation of voids, surface status and appearance with respect to various additively manufactured metal alloys. In addition, this article reviewed about the printing challenges pertaining to cracks and void formation, behaviour of material, merits and limitations and layer by layer printed material appearance. Overall, this article gives an overview of metal additive manufacturing, including its benefits and limitations as a criterion for further research in additive manufacturing.
Recent Progress in Hybrid Additive Manufacturing of Metallic Materials
Applied Sciences
Additive Manufacturing (AM) is an advanced technology that has been primarily driven by the demand for production efficiency, minimized energy consumption, and reduced carbon footprints. This process involves layer-by-layer material deposition based on a Computer-Aided Design (CAD) model. Compared to traditional manufacturing methods, AM has enabled the development of complex and topologically functional geometries for various service parts in record time. However, there are limitations to mass production, the building rate, the build size, and the surface quality when using metal additive manufacturing. To overcome these limitations, the combination of additive manufacturing with traditional techniques such as milling and casting holds the potential to provide novel manufacturing solutions, enabling mass production, improved geometrical features, enhanced accuracy, and damage repair through net-shape construction. This amalgamation is commonly referred to as hybrid manufacturing or...
Overview of Materials Qualification Needs for Metal Additive Manufacturing
JOM, 2016
This overview highlights some of the key aspects regarding materials qualification needs across the additive manufacturing (AM) spectrum. AM technology has experienced considerable publicity and growth in the past few years with many successful insertions for non-mission-critical applications. However, to meet the full potential that AM has to offer, especially for flightcritical components (e.g., rotating parts, fracture-critical parts, etc.), qualification and certification efforts are necessary. While development of qualification standards will address some of these needs, this overview outlines some of the other key areas that will need to be considered in the qualification path, including various process-, microstructure-, and fracture-modeling activities in addition to integrating these with lifing activities targeting specific components. Ongoing work in the Advanced Manufacturing and Mechanical Reliability Center at Case Western Reserve University is focusing on fracture and fatigue testing to rapidly assess critical mechanical properties of some titanium alloys before and after post-processing, in addition to conducting nondestructive testing/evaluation using micro-computerized tomography at General Electric. Process mapping studies are being conducted at Carnegie Mellon University while large area microstructure characterization and informatics (EBSD and BSE) analyses are being conducted at Materials Resources LLC to enable future integration of these efforts via an Integrated Computational Materials Engineering approach to AM. Possible future pathways for materials qualification are provided.