A Review of Residual Stress and Deformation Modeling for Metal Additive Manufacturing Processes

Rashid, Asim; Gopaluni, Aditya

doi:10.1016/j.cjmeam.2023.100102

Cited by 3 publications

(3 citation statements)

References 156 publications

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“…These features hinder the movement of electrons, thereby reducing the overall thermal conductivity. The rapid melting and cooling rate during LPBF induced the grain refinement and increased residual stresses [ 54 , 55 ]. As a result, the Vickers hardness of LPBF S800 Ag, which is 3.66 times higher than that of mould casting, significantly enhances material strength and abrasion resistance, the application range of silver alloys will be further expanded.…”

Section: Resultsmentioning

confidence: 99%

High-Quality Spherical Silver Alloy Powder for Laser Powder Bed Fusion Using Plasma Rotating Electrode Process

Li,

Zhang,

Chen

et al. 2024

Micromachines

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The plasma rotating electrode process (PREP) is an ideal method for the preparation of metal powders such as nickel-based, titanium-based, and iron-based alloys due to its low material loss and good degree of sphericity. However, the preparation of silver alloy powder by PREP remains challenging. The low hardness of the mould casting silver alloy leads to the bending of the electrode rod when subjected to high-speed rotation during PREP. The mould casting silver electrode rod can only be used in low-speed rotation, which has a negative effect on particle refinement. This study employed continuous casting (CC) to improve the surface hardness of S800 Ag (30.30% higher than mould casting), which enables a high rotation speed of up to 37,000 revolutions per minute, and silver alloy powder with an average sphericity of 0.98 (5.56% higher than gas atomisation) and a sphericity ratio of 97.67% (36.28% higher than gas atomisation) has been successfully prepared. The dense S800 Ag was successfully fabricated by laser powder bed fusion (LPBF), which proved the feasibility of preparing high-quality powder by the “CC + PREP” method. The samples fabricated by LPBF have a Vickers hardness of up to 271.20 HV (3.66 times that of mould casting), leading to a notable enhancement in the strength of S800 Ag. In comparison to GA, the S800 Ag powder prepared by “CC + PREP” exhibits greater sphericity, a higher sphericity ratio and less satellite powder, which lays the foundation for dense LPBF S800 Ag fabrication.

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Section: Resultsmentioning

confidence: 99%

High-Quality Spherical Silver Alloy Powder for Laser Powder Bed Fusion Using Plasma Rotating Electrode Process

Li,

Zhang,

Chen

et al. 2024

Micromachines

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“…Residual stress and deformation are major challenges facing the application of MAM [74]. Residual stresses in manufactured parts are often caused by the extreme thermal, mechanical, and metallurgical conditions in MAM [75].…”

Section: Metalsmentioning

confidence: 99%

Energy Efficiency in Additive Manufacturing: Condensed Review

Fidan,

Naikwadi,

Alkunte

et al. 2024

Technologies

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Today, it is significant that the use of additive manufacturing (AM) has growing in almost every aspect of the daily life. A high number of sectors are adapting and implementing this revolutionary production technology in their domain to increase production volumes, reduce the cost of production, fabricate light weight and complex parts in a short period of time, and respond to the manufacturing needs of customers. It is clear that the AM technologies consume energy to complete the production tasks of each part. Therefore, it is imperative to know the impact of energy efficiency in order to economically and properly use these advancing technologies. This paper provides a holistic review of this important concept from the perspectives of process, materials science, industry, and initiatives. The goal of this research study is to collect and present the latest knowledge blocks related to the energy consumption of AM technologies from a number of recent technical resources. Overall, they are the collection of surveys, observations, experimentations, case studies, content analyses, and archival research studies. The study highlights the current trends and technologies associated with energy efficiency and their influence on the AM community.

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“…To improve the adaptability of Ti scaffolds, Laser powder bed fusion (LPBF) is used to manufacture personalised Ti scaffolds, which can match the defect site well and avoid the drawbacks of conventional Ti scaffolds in clinical practice [14][15][16]. LPBF could be used to make complex geometries and obtained controlled internal pore architectures [17,18].…”

mentioning

confidence: 99%

Microstructure development of Ti scaffold by laser powder bed fusion with chemical polishing and its mechanical properties, biocompatibility

Lu,

Chen,

et al. 2024

Biosurface and Biotribology

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Titanium (Ti) dental scaffolds are widely used in dental prosthetics due to their excellent mechanical properties and biocompatibility. However, conventional Ti scaffolds manufactured through machining often do not fit perfectly with the bone defect site. Laser powder bed fusion (LPBF) technology enables the personalised manufacturing of custom‐made Ti scaffolds. A custom‐made Ti scaffold was prepared using LPBF and its surface roughness was improved through chemical polishing. To enhance the surface roughness, a nitric acid mixed solution with a specific composition of HF: HNO3:C3H6O3 = 2:2:3 was used. The polishing mechanism was investigated by adjusting the F/Ti ratio to control the formation and dissolution of the oxide film. As a result, the surface of the Ti scaffold after polishing exhibited a smooth and flat appearance compared to the LPBF part, with a reduced surface roughness (Ra) of 1.23 ± 0.19 μm. The custom‐made Ti scaffold also demonstrated favourable mechanical properties, with a bending strength of 335.18 ± 33.62 MPa and stiffness of 2.13 ± 0.21 GPa. Furthermore, in vitro cell tests confirmed the excellent biocompatibility of the custom‐made Ti scaffold. The authors present a feasible strategy for the further clinical application of custom‐made Ti scaffolds, offering enhanced surface properties and addressing the limitations of conventional machining methods.

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A Review of Residual Stress and Deformation Modeling for Metal Additive Manufacturing Processes

Cited by 3 publications

References 156 publications

High-Quality Spherical Silver Alloy Powder for Laser Powder Bed Fusion Using Plasma Rotating Electrode Process

High-Quality Spherical Silver Alloy Powder for Laser Powder Bed Fusion Using Plasma Rotating Electrode Process

Energy Efficiency in Additive Manufacturing: Condensed Review

Microstructure development of Ti scaffold by laser powder bed fusion with chemical polishing and its mechanical properties, biocompatibility

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