METAL ADDITIVE MANUFACTURING

openThis thesis focuses on metal additive manufacturing (MAM). It is a process that uses fine, metal powders to create strong, complex components that are designed either by using a computer-aided design (CAD) program or by taking a 3D scan of the object. There are many types of metal additive manufacturing processes, and each comes with its own advantages and disadvantages. Common types of metal additive manufacturing include: powder bed fusion, directed energy deposition, binder jetting and sheet lamination. Then the most significant process parameters concerning Ti6Al4V alloys manufactured with MAM processes are highlighted

Material Analysis of 3D Welded 5356 Aluminum Alloy

Metal 3D printing has been reserved for aerospace and high-end automotive industries because of its cost. A gas metal arc welder (GMAW) on a rugged 3D printer frame could make metal additive manufacturing an option for more industries and consumers. 3D welded aluminum has not been examined in depth as an option for additive manufacturing (AM). Extensive tests are necessary to determine the correct settings to use a metal inert gas (MIG) welder for AM. Porosity within the welded material must be evaluated to better understand the additive process. The material properties of 3D welded aluminum will be tested and compared to existing additive and traditional manufacturing methods. If strong enough this could reduce the cost of aerospace expeditions making tools like CubeSats more accessible to lower budget entities. Additionally, metal additive manufacturing could become more available and cost effective to use in any industry that requires manufacturing

ADDITIVE MANUFACTURING HOLLOW METAL PARTS WITH LIQUID METAL

Liquid-metal additive manufacturing is a new technology whose limits have not been fully tested. Unique molten-metal droplet printing allows for new metal structures to be made that cannot be built with traditional (powder)-based metal additive manufacturing. This research focuses on the potential to build hollow metal parts with no secondary manufacturing. The research provides a brief background in additive manufacturing and the reason for choosing liquid-metal jet printing. Multiple experiments are performed to test the design limitations of the additive manufacturing printer chosen. This leads to the design of the hollow metal part configurations that are ultimately buckling tested to prove they can support substantial sea pressure. As for the applicability of this research, it focuses on the buoyancy potential of the hollow parts and the potential use they could be to the undersea warfare community.Lieutenant, United States NavyApproved for public release. Distribution is unlimited

Emerging tools in casting technology and future of Aalto ENG foundry

Casting is the oldest metal manufacturing process known to humans. While the competence of casting technology has kept it popular since its advent, recent development in additive manufacturing has disrupted the status quo to some extent. Additive manufacturing is both acting as a competition through direct metal printing and also revolutionizing the casting technology through its inclusion at foundries in many different ways. This work starts with a literary study of comparison between casting and metal additive manufacturing. After wards, it discusses the emerging tools of casting technology which are becoming popular, many of which are possible through different additive manufacturing technologies. At the end, recommendations are given as to which of these tools could be implemented at Aalto Engineering foundry lab

Additive Manufacturing Research and Applications

This Special Issue book covers a wide scope in the research field of 3D-printing, including: the use of 3D printing in system design; AM with binding jetting; powder manufacturing technologies in 3D printing; fatigue performance of additively manufactured metals, such as the Ti-6Al-4V alloy; 3D-printing methods with metallic powder and a laser-based 3D printer; 3D-printed custom-made implants; laser-directed energy deposition (LDED) process of TiC-TMC coatings; Wire Arc Additive Manufacturing; cranial implant fabrication without supports in electron beam melting (EBM) additive manufacturing; the influence of material properties and characteristics in laser powder bed fusion; Design For Additive Manufacturing (DFAM); porosity evaluation of additively manufactured parts; fabrication of coatings by laser additive manufacturing; laser powder bed fusion additive manufacturing; plasma metal deposition (PMD); as-metal-arc (GMA) additive manufacturing process; and spreading process maps for powder-bed additive manufacturing derived from physics model-based machine learning

Metal Powder Additive Manufacturing

The beginning of the chapter is devoted to methods of receiving of metal powders—initial components for metal additive manufacturing. Initial materials are very important part of manufacturing, because their quality has an influence on stability of production process and quality of final product. There are various methods of metal powder synthesis. They may be separated conventionally on physical–chemical and mechanical ones. The physical–chemical methods are associated with physical and chemical transformations, and chemical composition and structure of the final product (metal powder) significantly differ from raw materials. The mechanical methods include various types of milling processes and jet dispersion melts by high pressure of gas or liquid (atomization). It is shown that the typical methods of quantitative estimation of powdered materials and some parameters for alloys that already were used in additive technologies. The next theme of the chapter is a review of additive technologies, initial materials for that is metal powders. At this moment, there are three main technologies that have found wide use for the production of metal parts from metal powders: binder jetting, directed energy deposition, and powder bed fusion. Each of them has unique peculiarity, advantages, and limitations that will be presented in the chapter

A study on ultrasonic energy assisted metal processing : its correeltion with microstructure and properties, and its application to additive manufacturing.

Additive manufacturing or 3d printing is the process of constructing a 3-dimensional object layer-by-layer. This additive approach to manufacturing has enabled fabrication of complex components directly from a computer model (or a CAD model). The process has now matured from its earlier version of being a rapid prototyping tool to a technology that can fabricate service-ready components. Development of low-cost polymer additive manufacturing printers enabled by open source Fused Deposition Modeling (FDM) printers and printers of other technologies like SLA and binder jetting has made polymer additive manufacturing accessible and affordable. But the metal additive manufacturing technologies are still expensive in terms of initial system cost and operating costs. With this motivation, this dissertation aims to develop and study a novel metal additive manufacturing approach called Acoustoplastic Metal Direct-Write (AMD) that promises to make metal additive manufacturing accessible and affordable. The process is a voxel based additive manufacturing approach which uses ultrasonic energy to manipulate and deposit material. This dissertation demonstrates that the process can fabricate near-net shape metal components in ambient conditions. This dissertation investigates two key phenomenon that govern the process. The first phenomenon investigated is ultrasonic/acoustic softening. It is the reduction in yield stress of the metals when being deformed under simultaneous application of ultrasonic energy. A detailed analysis of the stress and microstructure evolution during ultrasonic assisted deformation has been presented in this dissertation. Crystal plasticity model modified on the basis of microstructure analysis has been developed to predict the stress evolution. The 2nd phenomenon investigated is ultrasonic energy assisted diffusion that enables the bonding of voxels during the AMD process. High resolution Transmission Electron Microscopy (HRTEM) and Energy Dispersive Spectroscopy (EDS) analysis has been used to quantify this phenomenon and also distinguish the process mechanics from other foil or sheet based ultrasonic joining processes

GRC Metal Additive Manufacturing

Presentation for the GRC Dialog Session with Ohio Materials Center of Excellenc

An analytic cost model for bound metal deposition

Metal material extrusion is a family of metal additive manufacturing that includes atomic diffusion additive manufacturing (ADAM) and bound metal deposition (BMD). In the literature, there are just a few cost models for ADAM and no one for BMD. The paper presents an analytic cost model for BMD. It considers the entire process: pre-processing, printing and post-processing. The total manufacturing cost is split into material, machine, labour, energy and consumables items. The cost model validation on a 3D-printed part determined an accuracy of 98%

A scalable parallel finite element framework for growing geometries. Application to metal additive manufacturing

This work introduces an innovative parallel, fully-distributed finite element framework for growing geometries and its application to metal additive manufacturing. It is well-known that virtual part design and qualification in additive manufacturing requires highly-accurate multiscale and multiphysics analyses. Only high performance computing tools are able to handle such complexity in time frames compatible with time-to-market. However, efficiency, without loss of accuracy, has rarely held the centre stage in the numerical community. Here, in contrast, the framework is designed to adequately exploit the resources of high-end distributed-memory machines. It is grounded on three building blocks: (1) Hierarchical adaptive mesh refinement with octree-based meshes; (2) a parallel strategy to model the growth of the geometry; (3) state-of-the-art parallel iterative linear solvers. Computational experiments consider the heat transfer analysis at the part scale of the printing process by powder-bed technologies. After verification against a 3D benchmark, a strong-scaling analysis assesses performance and identifies major sources of parallel overhead. A third numerical example examines the efficiency and robustness of (2) in a curved 3D shape. Unprecedented parallelism and scalability were achieved in this work. Hence, this framework contributes to take on higher complexity and/or accuracy, not only of part-scale simulations of metal or polymer additive manufacturing, but also in welding, sedimentation, atherosclerosis, or any other physical problem where the physical domain of interest grows in time