Additive manufacturing (AM) is becoming a more and more widespread (and trendy) approach. Its flexibility and capability to manufacture any topology has opened new possibilities: AM could lead to significant performance improvements thanks to the exploitation of lattice or reticular structures as partial replacement of the traditional solid design. The potential of this technology knows no bounds. However, in the real world, the lower performances of the materials and the high manufacturing costs significantly restrict the fields of application for which the adoption of AM results effective. In this context, the mechanical static and fatigue properties of a 17-4 PH stainless steel produced via AM were experimentally measured and compared with those of the wrought material to quantify the performance reduction. Based on these data, three components, namely a hip prosthesis, a blow plastic bottle die, and an automotive gear were selected as representative examples to show the pros and contra of AM. The three components were chosen because they belong to three quite dissimilar fields and are produced in different batch sizes. The three original designs were specifically optimized for AM by means of finite element (FE) simulations. The new solutions fulfil the strength requirements of the original parts showing at the same time reduced weights and inertias. The traditional and new designs were compared in terms of production times and costs to quantify the real benefits of AM for different applications.
In this paper, the static and low-cycle-fatigue (LCF) behavior of wrought samples of 17-4 PH stainless steel (SS) manufactured via Selective Laser Melting (SLM) are presented. On the one hand, several scholars have studied SLM materials and literature reports a huge amount of data as for the high-cycle-fatigue (HCF) behavior. On the other hand, few are the data available on the LCF behavior of those materials. The aim of the present research is to provide reliable data for an as-build 17-4 PH steel manufactured via SLM techniques. Only with quantitative data, indeed, it is possible to exploit all the advantages that this technology can offer. In this regard, both quasi-static (QS) and low-cycle-fatigue tests were performed on Additive Manufacturing (AM) cylindrical samples. Through QS tests, the constitutive low has been defined. Strain-controlled fatigue tests on an electromechanical machine were performed on 12 samples designed according to the ASTM standard. Tests were continued also after the stabilization was reached (needed for the cyclic curve described with the Ramberg-Osgood equation) to obtain also the fatigue (ε-N) curve. Results show that the material has a softening behavior. The Basquin-Coffin-Manson (BCM) parameters were tuned on the basis of the ε-N combinations after rupture.
Additive Manufacturing (AM) is becoming a more and more widespread (and trendy) approach. Its flexibility and capability to manufacture any topology has opened new possibilities: AM could lead to significant performance improvements thanks to the exploitation of lattice or reticular structures as partial replacement of the traditional solid design. The potential of this technology knows no bounds. However, in the real world, the lower performances of the materials and the high manufacturing costs significantly restrict the fields of application for which the adoption of AM results effective. In this context, the mechanical static and fatigue properties of a 17-4 PH Stainless Steel produced via AM were experimentally measured and compared with those of the wrought material to quantify the performance reduction. Based on these data, three components, namely a hip prosthesis, a blow plastic bottle die, and an automotive gear were selected as representative examples to show the pros and contra of AM. The three components were chosen because they belong to three quite dissimilar fields and are produced in different batch sizes. The three original designs were specifically optimized for AM by means of Finite Element (FE) Simulations. The new solutions fulfil the strength requirements of the original parts showing at the same time reduced weights and inertias. The traditional and new designs were compared in terms of production times and costs to quantify the real benefits of AM for different applications.
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