Advances in metal additive manufacturing: A review of common processes, industrial applications, and current challenges

© 2021 by the authors. Licensee MDPI, Basel, Switzerland. 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 comprehen-sive 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 current limitations and challenges, which prevent industries to fully benefit from the metal AM opportunities, including production volume, standards compliance, post processing, product quality, maintenance, and materials range. Overall, this paper provides a survey as the benchmark for future industrial applications and research and development projects, in order to assist industries in selecting a suitable AM technology for their application

Thermo-hydraulic performance evaluation of a NACA 63-015 heat exchanger with shark denticles as surface textures

In this study, the effect of using bio-inspired surface texturing as a technique to further enhance the efficiency of a single Plate Fin Heat Exchanger (PFHX) was investigated experimentally. By using biomimicry across disciplines, the denticle, which is a body adaptation from shark skin for enhanced hydrodynamics, was identified as a surface texture to be used on the fin of a PFHX. A smooth NACA 63-015 PFHX (HX0) was used as baseline for thermo-hydraulic performance comparisons. Initially, three PFHXs (HX1, HX2 and HX3), consisting of arrays of denticles upscaled to different scale factors, were designed and printed in ABS plastic to evaluate Additive Manufacturing (AM) limits. By analysing optical images and pressure drop results, HX2 was found to be the best performing array in terms of printing quality and pressure drop performance. Both HX0 and HX2 were then printed in stainless steel 17-4PH by using a Markforged Metal X printer, and then experimentally compared to evaluate their flow and heat transfer behaviours. Results demonstrate that the addition of shark denticles as surface textures on HX2 shifted the onset of turbulence from a fully turbulent to a transitional regime compared to HX0. For Re \u3c 5.7×104, the friction factor for HX2 was less than that of HX0, while at higher Re values the trend was reversed due to increases in skin friction drag. At Re = 3.9×104, the friction factor for HX2 was 56% lower than that of HX0. Overall, a mean improvement of 14% in Nusselt number was noted for HX2 compared to HX0. Further, a mean thermo-hydraulic performance of 1.11 was noted for HX2 for the range of tested Re values, which demonstrated that the addition surface textures in the form of shark denticles to a NACA 63-015 profile yielded a more efficient PFHX compared to a smooth one

Experimental investigation and comparison of the thermal performance of additively and conventionally manufactured heat exchangers

Air heat exchangers (HXs) are applicable in many industrial sectors because they offer a simple, reliable, and cost-effective cooling system. Additive manufacturing (AM) systems have sig-nificant potential in the construction of high-efficiency, lightweight HXs; however, HXs still mainly rely on conventional manufacturing (CM) systems such as milling, and brazing. This is due to the fact that little is known regarding the effects of AM on the performance of AM fabricated HXs. In this research, three air HXs comprising of a single fin fabricated from stainless steel 316 L using AM and CM methods—i.e., the HXs were fabricated by both direct metal printing and milling. To eval-uate the fabricated HXs, microstructure images of the HXs were investigated, and the surface roughness of the samples was measured. Furthermore, an experimental test rig was designed and manufactured to conduct the experimental studies, and the thermal performance was investigated using four characteristics: heat transfer coefficient, Nusselt number, thermal fluid dynamic performance, and friction factor. The results showed that the manufacturing method has a considerable effect on the HX thermal performance. Furthermore, the surface roughness and distribution, and quantity of internal voids, which might be created during and after the printing process, affect the performance of HXs