A Review on Status of Research in Metal Additive Manufacturing

Kannan, Ganesa Balamurugan; Rajendran, Dinesh Kumar

doi:10.1007/978-981-10-0812-2_8

Cited by 24 publications

(16 citation statements)

References 9 publications

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“…There are visible pores on the sample with a side length of 15 mm, which was produced using the optimizing procedure for SLM method (Figure 4c). The samples had a similar density of 99.2% and 99.4% of the theoretical value (4.43 g/cm 3 ) for the 5-mm SLM samples and 15-mm EBM sample, respectively. The 15-mm SLM sample had a density of 98.1% of the theoretical value.…”

Section: Light Microscopymentioning

confidence: 77%

“…AM is a process that fuses materials layer by layer, to produce items based on 3D model data. Various AM methods differ in terms of the raw materials used and in the ways for material consolidation [2,3]. This work focuses on AM techniques where a raw material is delivered in a form of powder and is consolidated via a laser beam or an electron beam.…”

Section: Introductionmentioning

confidence: 99%

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Laser and Electron Beam Additive Manufacturing Methods of Fabricating Titanium Bone Implants

et al. 2017

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Featured Application: This work is a detailed comparison of the direct laser and electron additive manufacturing methods, which could help scientific research institutes and companies choose the best 3D printer system for the fabrication of titanium implants.Abstract: Additive Manufacturing (AM) methods are generally used to produce an early sample or near net-shape elements based on three-dimensional geometrical modules. To date, publications on AM of metal implants have mainly focused on knee and hip replacements or bone scaffolds for tissue engineering. The direct fabrication of metallic implants can be achieved by methods, such as Selective Laser Melting (SLM) or Electron Beam Melting (EBM). This work compares the SLM and EBM methods used in the fabrication of titanium bone implants by analyzing the microstructure, mechanical properties and cytotoxicity. The SLM process was conducted in an environmental chamber using 0.4-0.6 vol % of oxygen to enhance the mechanical properties of a Ti-6Al-4V alloy. SLM processed material had high anisotropy of mechanical properties and superior UTS (1246-1421 MPa) when compared to the EBM (972-976 MPa) and the wrought material (933-942 MPa). The microstructure and phase composition depended on the used fabrication method. The AM methods caused the formation of long epitaxial grains of the prior β phase. The equilibrium phases (α + β) and non-equilibrium α' martensite was obtained after EBM and SLM, respectively. Although it was found that the heat transfer that occurs during the layer by layer generation of the component caused aluminum content deviations, neither methods generated any cytotoxic effects. Furthermore, in contrast to SLM, the EBM fabricated material met the ASTMF136 standard for surgical implant applications.

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Section: Light Microscopymentioning

confidence: 77%

Section: Introductionmentioning

confidence: 99%

Laser and Electron Beam Additive Manufacturing Methods of Fabricating Titanium Bone Implants

et al. 2017

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“…This helps strengthen supply chains and boosts their profitability and flexibly [3]. Presently, AM has been successfully exploited in electronic, aerospace and biomedical industries where highly specialized and customizable components are required [4][5][6][7]. The selective laser melting (SLM) technique makes especially great strides in the field of metal AM.…”

Section: Introductionmentioning

confidence: 99%

“…Though noticeable progress has been made, there have been some challenging issues that still need addressing to allow AM and SLM to be used among mainstream manufacturing processes. Limited precision of the fabricated products and the repeatability of the processes are considered especially high technological barriers to the maturation of additive manufacturing techniques [4]. In particular, AM parts are often built with high surface roughness, which necessitates some post processing steps to refine the resultant roughness and makes it suitable for a wide range of engineering applications.…”

Section: Introductionmentioning

confidence: 99%

Effect of Process Parameters on the Generated Surface Roughness of Down-Facing Surfaces in Selective Laser Melting

et al. 2019

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Additive manufacturing provides a number of benefits in terms of infinite freedom to design complex parts and reduced lead-times while globally reducing the size of supply chains as it brings all production processes under one roof. However, additive manufacturing (AM) lags far behind conventional manufacturing in terms of surface quality. This proves a hindrance for many companies considering investment in AM. The aim of this work is to investigate the effect of varying process parameters on the resultant roughness of the down-facing surfaces in selective laser melting (SLM). A systematic experimental study was carried out and the effects of the interaction of the different parameters and their effect on the surface roughness (Sa) were analyzed. It was found that the interaction and interdependency between parameters were of greatest significance to the obtainable surface roughness, though their effects vary greatly depending on the applied levels. This behavior was mainly attributed to the difference in energy absorbed by the powder. Predictive process models for optimization of process parameters for minimizing the obtained Sa in 45° and 35° down-facing surface, individually, were achieved with average error percentages of 5% and 6.3%, respectively, however further investigation is still warranted.

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“…Though the aluminum part properties and geometrical accuracy obtained by subtractive and formative manufacturing are well-established, these have been understudied with AM technologies [10].…”

Section: Introductionmentioning

confidence: 99%

Anisotropy of additively manufactured AlSi10Mg: threads and surface integrity

Ullah

Akmal

Laakso

et al. 2020

Int J Adv Manuf Technol

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Implementing additive manufacturing in an industry, particularly for critical applications of lightweight aluminum (AlSi10Mg), requires part properties that are both accurate and precise to conform to the intent of a robust design. In this experimental study, the objective was to evaluate anisotropy in part properties (i.e., flatness, surface roughness, surface porosity, surface hardness, pre-hole shrinkage, drilling thrust force, and thread-stripping force) when the part orientation (i.e., print inclination and recoater angle) was independently changed. This study developed and investigated an innovative procedure for determining anisotropy in part properties. The part properties were evaluated by designing specific features on a tailor-made flat plate. The replicas of the aluminum plate were additively manufactured at varying orientations using two commercial EOS parameter sets for the laserbased powder bed fusion technique. Conventional measurement equipment was used to analyze all the part properties, except the thread-stripping force, which was measured using a custom-made setup. All the part properties indicated a considerable degree of anisotropy, excluding the drilling thrust force. The printing parameters dictate the significance of the anisotropy. The anisotropy in flatness and pre-hole shrinkage decreases with an increased substrate temperature and a decrease in energy input and thermal gradient. The presence of surface overlapping contours in the scan strategy and an increased energy input can reduce anisotropy in surface roughness and hardness. No significant anisotropy was detected when the recoater angle was changed. This study helps designers establish and substantiate design for additive manufacturing that is within the limits of appropriate anisotropy for a robust design.

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A Review on Status of Research in Metal Additive Manufacturing

Cited by 24 publications

References 9 publications

Laser and Electron Beam Additive Manufacturing Methods of Fabricating Titanium Bone Implants

Laser and Electron Beam Additive Manufacturing Methods of Fabricating Titanium Bone Implants

Effect of Process Parameters on the Generated Surface Roughness of Down-Facing Surfaces in Selective Laser Melting

Anisotropy of additively manufactured AlSi10Mg: threads and surface integrity

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