The speech will also focus on the production of Metal Powders and Powder Metallurgical Steels and especially its associated production technologies like HIP, MIM and AM. As they are and will become key future core technologies for a number of demanding products and thus for the usage in different associated industries. The presentation will also highlight the actual supply and demand situation...
Additive manufacturing has made significant progress in recent years, particularly with the advent of next-generation technologies. This lecture explores cutting-edge innovations that are reshaping the Additive Manufacturing landscape and propelling it into a new frontier. The focus is on innovative AM processes, including the state-of-the-art of processing of metallic materials such as Ti-,...
Additive Manufacturing technologies are growing rapidly and moving towards industrial-grade production technology; however the development and qualification of materials and processes remain time-consumingand costly challenges for faster AM adoption. An integrated multi-scale approach designed to accelerate AM materials and process development and qualification will be discussed as a potential...
The different technologies in Metal Additive Manufacturing evolved to a technology and manufacturing readiness to apply them in serial production of functional as well as critical parts. Still industrialization in datamanagement, automation and lean production is ongoing to enable a stronger penetration in the manufacturing sector. An overview with production examples is given on the progress...
Abstract
This work investigates the corrosion morphology of AISI 316L stainless steel produced by laser powder bed fusion (L-PBF). The behavior of the as printed surface is compared with that of the bulk material to understand the effect of microstructure and roughness of the as printed surface on its corrosion behavior.
The L-PBF specimens investigated in this work were manufactured with...
The limitations of existing additive manufacturing processes often include long printing times and time-consuming post-processing steps due to the removal of components from a powder bed or the removal of support structures.
The MoldJet® process developed by Tritone® Technologies Ltd. is a sinter-based additive manufacturing process that is equally suitable for the productive fabrication of...
The 3D Master method aims to reduce effort and misinterpretation while transferring product information from the design office to the production department, thanks to 3D model files containing all the product manufacturing information (PMI).
Thus, for a metal additive manufacturing (MAM) part, the 3D Master method gives direct access to crucial data, such as the product’s materials and 3D...
Laser Powder Bed Fusion (LPBF) remains a predominant process in the additive manufacturing for metals, and is widely adopted by equipment manufacturers, within research circles, and across a spectrum of industrial applications. Despite its prominence, LPBF faces inherent limitations regarding the complexity of geometries it can produce, the diversity of processable materials, and its overall...
This study reports on the oxygen content measured by EDX analysis of samples which were heat treated in either atmospheric pressure or in high vacuum. The samples were manufactured by Laser-Powder-Bed Fusion (L-PBF) technology, where subsequent heat treatment is required. In theory and in practice, it could be shown, that oxygen in high vacuum is always lower than at atmospheric pressure. This...
The advantages of the PBF-LB/M process, such as geometric complexity due to increased design freedom or function integration, offer great potential for optimizing products in the automotive sector. However, it often does not go beyond prototyping and small series, as productivity is too low for the required quantities and economies of scale can rarely be exploited lucratively. In the field of...
The Indian gold jewelry industry, a cornerstone of the nation's cultural heritage and economic engine, faces challenges like rising gold prices and limited design flexibility in traditional manufacturing methods. This paper explores the potential of Binder Jet 3D printing as a disruptive innovation to revolutionize the industry. We delve into established gold jewelry manufacturing processes,...
Additive manufacturing technology has initiated a transformative phase in the industrial landscape, particularly in the realm of metal 3D printing. A key element for the success of this revolutionary manufacturing method lies in the availability of high-quality metal powders that meet the specific requirements of various applications. This work sheds light on the innovative development of new...
This study investigates the utilization of machine learning for optimizing additive manufacturing processes, focusing on Laser PowderBed Fusion (L-PBF) and Laser Metal Deposition (LMD). By leveraging domain expertise, machine learning demonstrates significant potential in enhancing efficiency and quality. Through specific case studies, we highlight the benefits and limitations of...
The heat evolution and thereby the densification rate in Laser Powder Bed Fusion (LPBF) Metal 3D Printing may vary during the print depending upon the build geometry variation along the height. Such variations in densification, even at fixed print parameters, are a major cause of defective parts in metal AM, as well as the poor consistency of print quality form part to part. We present a...
The development of new alloys for additive manufacturing, aiming at specific tailored properties, constitutes a topic of high interest.
• For instance, aluminum alloys are gaining significant attention in additive manufacturing, with numerous commercial alloys entering the market. However, most of these alloys primarily target Laser Powder Bed Fusion (L-PBF) applications i.e., they are...
A powder bed fusion – laser beam / metal (PBF-LB/M) process and hot isostatic pressing (HIP) combined producing route was developed to manufacture nitrogen (N) in high-alloyed stainless steels in which mechanically mixed base AISI stainless steel 304L (SS304L) powder and silicon nitride (Si3N4) powder was manufactured by PBF-LB/M and further homogenized by HIP. Due to the partially undissolved...
To enable the industrial use of wire-arc additive manufacturing (WAAM), it is crucial to provide a stable and sophisticated process. However, due to the large number of internal and external disturbances, the complex dynamic thermal conditions of these systems are difficult to handle. To overcome these problems, this paper presents a modular closed-loop methodology for optimizing process...
Metal powders used in additive manufacturing (AM) are expensive and energy-intensive to manufacture desired engineering parts. Reusing these powders reduces material waste, lowers production costs, and minimizes the environmental footprint of AM processes to support sustainable manufacturing routes. Therefore, this study investigates the reusability/degradation of CX steel powders via laser...
Weight reduction is crucial for transport industries (like aerospace), it is possible to achieve through topological optimization or by implementing lattice structures. This objective can be obtained by additive manufacturing processes. Besides, sustainability concerns are important and the use of upcycled powder feedstocks can be noteworthy. In the current study, we present an upcycling...
The development history of LPBF began 30 years ago at the Fraunhofer ILT in Aachen. LPBF is now the most important additive manufacturing process for metalliccomponents. This presentation will take a look back at the beginnings of the process and the key development steps, present the current technological and economic status and provide an insight into current development trends.
Additive manufacturing (AM), particularly Laser Powder Bed Fusion (LPBF), is rapidly advancing due to its increasing adoption as an advanced manufacturing technique capable of producing intricate and reliably consistent parts. However, this heightened interest in AM has prompted concerns regarding its sustainability. In response, a recent study conducted a comprehensive experimental effort...
Investigation of 3D Plasma Metal Deposition (3DPMD) with Aluminium powder
D. Vieweger1*, Y. Tong1, P. Mayr1
1 Technical University of Munich, Chair of Materials Engineering of Additive Manufacturing
*daniel.vieweger@tum.de
As additive manufacturing (AM)...
Limitations in bulk metallic glass (BMG) additive manufacturing arise from the relaxation of solidified layers, diminishing free volume, and adversely affecting part quality. The first generation of freeform laser beam shaping technology has demonstrated its capacity to produce Zr-based BMG test coupons devoid of any detectable crystalline phases, thereby minimizing the reheating of preceding...
The energy sector uses a large amount of moving metallic parts, for example stainless steel pumps or collectors. Such kind of parts can be damaged during the use life and small cracks can appear after some years. Classically, the cracks are manually repaired with conventional welding techniques and the parts can still be used several years after the repair. However, the manual repair leads to...
Adaptive process control strategies for variable wall thickness in laser metal deposition: a framwork utilizing articifical neural networks
Henrik Kruse, Jan Theunissen, Johannes Henrich Schleifenbaum – RWTH Aachen University, Chair for Digital Additive Production DAP, Germany
ABSTRACT
Laser Metal Deposition (LMD) offers significant potential for optimizing local component...
Remanufacturing is a comprehensive and rigorous industrial process by which a previously sold, leased, used, worn, remanufactured, or non-functional product or part is returned to a like-new, same-as-when-new, or better-than-when-new condition from both a quality and performance perspective, through a controlled, reproducible, and sustainable process. Remanufacturing is an archetype of a...
The landscape of LPBF process has evolved significantly during recent years, exceeding its origins in simple test production and prototyping towards manufacturing functional parts for real-world applications. Despite its potential, the current limitations in cost and efficiency of the process have held back the broader application of metal 3D printing. Various solutions have been proposed, yet...
Porous materials have always been a necessary component in application of catalysts, fuel cells or capacitors in the field of energy conversion and storage. They can be obtained by a variety of production methods, however a novel emerging method has been demonstrated by the use of additive manufacturing. With laser powder bed fusion (LPBF) several printing parameters, such as laser power,...
Molten Metal Deposition (MMD) represents an advanced wire-based aluminum additive manufacturing (AM) methodology wherein wire feedstock is directly liquified and extruded onto a heated substrate. This technique obviates the necessity for auxiliary energy sources such as lasers, as well as binders or additional support structures, thereby mitigating thermal stress implications and enhancing...
Laser powder bed fusion (L-PBF) has become a widely used process in the additive manufacturing of metals, for it combines the assets of a high degree of freedom in the design of parts with a high flexibility in the production process itself. In addition, material properties of L-PBF parts have been demonstrated to be able to equal or, in some cases, even exceed those of comparable, yet...
Laser Powder Bed Fusion (L-PBF) technology offers the capability to manufacture a diverse range of components and features, which span from thin or hollow structures to massive elements. Typically, the primary parameters in the L-PBF process, such as laser power, scan speed, and hatching distance, are optimized for components with significant print areas, which can be divided into core and...
This study explores a sustainable approach within the metal Additive Manufacturing (AM) field by focusing on the reuse of AlMg10Si waste powder from Laser Beam Powder Bed Fusion (LBPF) processes in Plasma Directed Energy Deposition (DED). Aimed at advancing material circularity, particularly for the automotive industry, this research investigates the mechanical properties and heat treatment...
In the field of Laser-Based Directed Energy Deposition (DED-LB) processes, real-time process monitoring is a critical aspect that ensures the quality and integrity of the final product. While established methods exist for monitoring other process signatures such as molten pool size and temperature, the monitoring of the layer thickness presents a unique challenge, especially for processes...
In a time characterized by uncertainty, metal 3D printing is undergoing a transition from a purely futuristic research endeavor to a technology that must demonstrate tangible profitability in real-world applications. Users must leverage the benefits of 3D printing, including design freedom and elimination of tooling costs, without investing additional time and resources in research. As one of...
The development of novel alloys that are specifically tailored for additive manufacturing (AM) is one of the current major challenges of the AM material science research community. However, the existing approaches can be further made efficient in exploring the vast material and process design space in AM.
In the present work, we applied extreme high-speed laser material deposition (EHLA)...
The surface finishing of complex metallic parts made by additive manufacturing, remains a challenge. Indeed, this kind of treatment is required to enhance the properties of the parts (cleanliness, mechanical properties, etc.) so that they are made compatible with their final use.
During this presentation, results of the FITFAME project (ESA GSTP GT1A-314MS), focusing on the finishing of...
Additive manufacturing processes are becoming increasingly popular. Metal Binder Jetting (MBJ) is emerging as a promising technique for high productivity in the simultaneous production of highly complex components. The limited number of materials available for MBJ creates a high potential for research. Especially in the field of nickel-free austenitic stainless steels, the choice of materials...
Fabrication of metal matrix composites with improved properties requires an understanding of how laser action interacts with ceramic fillers and metal matrices in laser powder bed fusion (LPBF) synthesis. This work investigates the dynamic behavior and chemical reactions that occur during LPBF synthesis when laser energy is applied to the interface between metal matrices and ceramic fillers....
Lightweight design is very closely associated with additive manufacturing. Besides the design possibilities offered by this technology, the material used also plays a key role. Especially in the LPBF process, the production of the powder and the processing of the material is a major challenge. This applies in particular to magnesium alloys as a lightweight material. Due to its low density and...
Within the presentation an overlook of Aconity3D’s endeavor in providing the first closed-loop power laser control of the applied laser sourceswithin L-PBF is given. At this, current progress and limitations are provided, highlighting the state of the art in fully controlled first-time right approaches which forms a precondition for truly industrial manufacturing via Additive Manufacturing.
Powder Bed Fusion of Metals with Laser Beam is an emerging Additive Manufacturing technology that builds metal parts layer by layer from metal powder. For each layer, metal powder is scanned and fused selectively by a laser beam to create a solid part. The laser follows a predetermined path at a specified speed and power defined in the scan strategy. This scan strategy determines the...
Additive manufacturing using wire arc technology has become increasingly popular in the generation of large-scale and complex shaped 3D parts. However, heat input and solidification shrinkage during deposition causes distortions and residual stresses. These can significantly affect the geometric accuracy and mechanical properties of the deposit. Process simulation offers the possibility to...
Integrated Computational Materials Engineering (ICME) expedites integration of Additive Manufacturing (AM) in industry by addressing emerging challenges. Common challenges include rapidly identifying process windows to avoid processing defects and optimizing materials compositions to align with property requirements of AM-fabricated components for high demand applications. This presentation...
In the Laser Powder Bed Fusion (LPBF) process, metallic components are manufactured layer by layer by selectively melting metal powder using laser radiation. While the additive manufacturing principle allows parts ofalmost unlimited complexity to be produced, LPBF process control strategies are largely static according to the state of the art and only take into account the component geometry...
In this research, investigation is focused on Laser Powder Bed Fusion (L-PBF) of non-standard titanium-molybdenum-aluminium-vanadium alloys. The aim of the research is to develop additive manufacturing (AM) process parameters that can achieve full density of titanium alloys with different molybdenum contents with satisfactory static (tensile strength) and dynamic (fatigue behaviour) mechanical...
High temperature alloys are used for aerospace applications e.g. turbine blades. Within this study, results on IN718 powder deposited with the Plasma Metal Deposition (PMD) will be compared with the Wire Arc Additive Manufacturing (WAAM) process. The IN718 alloys have been prepared to improve their mechanical properties and characterize them at high temperatures of ~800°C to 1000°C. With...
Forging tools endure extreme conditions, being subjected to both high temperatures and mechanical stresses on their operational surfaces. Enhancing resistance to external influences is crucial for extending their service life. This paper investigates the efficacy of incorporating a material layer, manufactured via Additive Manufacturing using Directed Energy Deposition (DED), to bolster the...
The bistable mechanisms use the deformation of the compliant segment (elastic deformation of the material) to transition from one equilibrium position to another. The deformation character eliminates friction and improves the reliability of the mechanism. Both the numerical model and experiments were used to determine the parameters of the bistable mechanism. The mechanism was designed to hold...
