A review on additive/subtractive hybrid manufacturing of directed energy deposition (DED) process

Dezaki, Mohammadreza Lalegani; Serjouei, Ahmad; Zolfagharian, Ali; Fotouhi, Mohammad; Moradi, Mahmoud; Ariffin, Mohd Khairol Anuar Mohd; Bodaghi, Mahdi

doi:10.1016/j.apmate.2022.100054

Cited by 59 publications

(30 citation statements)

References 159 publications

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“…[7][8][9] Even though 3D printing offers different advantages, such as rapid prototyping, fewer material compositions, faster production, product customization, and comprehensive material selection, each 3D printing technique has certain limitations. For example, the extrusion-based approach generates defects, such as delamination and void formation; 10 the vat polymerization technique has a limited build size from resins and light control; 11 the material jetting-based printing requires suitable inks, considering their viscoelastic properties and wettability with substrates; 12 the PBF-based printing generates components that have a low mechanical strength and limited surface finish; 13 the DED-based printing requires post-processing of components due to high surface roughness; 14 and LOM needs decubing with a labor-intensive process. 15 Some defects may significantly deteriorate the performance of 3D-printed components.…”

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confidence: 99%

Hybrid 3D printing for highly efficient nanoparticle micropatterning

et al. 2023

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Hybrid 3D printing for highly efficient nanoparticle micropatterning

et al. 2023

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“…Hybridization opens infinite possibilities for enhancing part quality improvement and production rates [ 60 ];…”

Section: Figurementioning

confidence: 99%

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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Additive manufacturing (AM), an enabler of Industry 4.0, recently opened limitless possibilities in various sectors covering personal, industrial, medical, aviation and even extra-terrestrial applications. Although significant research thrust is prevalent on this topic, a detailed review covering the impact, status, and prospects of artificial intelligence (AI) in the manufacturing sector has been ignored in the literature. Therefore, this review provides comprehensive information on smart mechanisms and systems emphasizing additive, subtractive and/or hybrid manufacturing processes in a collaborative, predictive, decisive, and intelligent environment. Relevant electronic databases were searched, and 248 articles were selected for qualitative synthesis. Our review suggests that significant improvements are required in connectivity, data sensing, and collection to enhance both subtractive and additive technologies, though the pervasive use of AI by machines and software helps to automate processes. An intelligent system is highly recommended in both conventional and non-conventional subtractive manufacturing (SM) methods to monitor and inspect the workpiece conditions for defect detection and to control the machining strategies in response to instantaneous output. Similarly, AM product quality can be improved through the online monitoring of melt pool and defect formation using suitable sensing devices followed by process control using machine learning (ML) algorithms. Challenges in implementing intelligent additive and subtractive manufacturing systems are also discussed in the article. The challenges comprise difficulty in self-optimizing CNC systems considering real-time material property and tool condition, defect detections by in-situ AM process monitoring, issues of overfitting and underfitting data in ML models and expensive and complicated set-ups in hybrid manufacturing processes.

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“…Consequently, oxide ceramics have shown great application potential in aerospace, energy chemical industry, and biomedical fields 1,2 . Nevertheless, the traditional solid‐phase sintered preparation process of raw material‐green body‐molding‐drying‐sintering‐finishing is time‐consuming and energy‐intensive 3,4 . More importantly, the addition of binders and sintering aids sacrifices the purity and density of ceramics, which severely affects their excellent performance in practical production.…”

Section: Introductionmentioning

confidence: 99%

“…1,2 Nevertheless, the traditional solid-phase sintered preparation process of raw material-green body-molding-drying-sinteringfinishing is time-consuming and energy-intensive. 3,4 More importantly, the addition of binders and sintering aids sacrifices the purity and density of ceramics, which severely affects their excellent performance in practical production. The development and application of directional solidification techniques, including the Bridgman method, 5 micro-pulling method, 6 laser floating zone method, 7 and the edge-defined film-fed growth, 8 have simplified the preparation process to a certain extent.…”

Section: Introductionmentioning

confidence: 99%

Cracking mechanism in laser directed energy deposition of melt growth alumina/aluminum titanate ceramics

Huang

et al. 2023

J Am Ceram Soc.

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Thanks to its advantages of high efficiency and near-net shaping, laser directed energy deposition (LDED) is rapidly becoming a remarkable preparation technology for high-purity ceramics. However, the cracking problem in shaping process is always a great challenge for LDED to achieve industrial application. For this purpose, alumina/aluminum titanate melt-growth ceramics (A/AT MGCs) were prepared using LDED system, and the corresponding finite element thermal analysis model was developed. The solidification behavior and cracking mechanism of A/AT MGCs were investigated based on the thermal analysis model, and the influence of process parameters on the cracking characteristics was revealed with experiments. Results show that the crack morphology and distribution are controlled by microstructure and temperature gradient together. The scanning speed of 100-150 mm/min, with better microstructure and lower temperature gradient, is a preferred process window. This study provides theoretical guidance and technical support for the cracking suppression during LDED shaping of ceramics.

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A review on additive/subtractive hybrid manufacturing of directed energy deposition (DED) process

Cited by 59 publications

References 159 publications

Hybrid 3D printing for highly efficient nanoparticle micropatterning

Hybrid 3D printing for highly efficient nanoparticle micropatterning

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

Cracking mechanism in laser directed energy deposition of melt growth alumina/aluminum titanate ceramics

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