A Review on the Metal Additive Manufacturing Processes

Tebianian, Mohaddeseh; Aghaie, Sara; Razavi Jafari, Nazanin Sadat; Elmi Hosseini, Seyed Reza; António Bastos Pereira, António; A.O. Fernandes, Fábio; Chen, Chao; Farbakhti, Mojtaba

doi:10.20944/preprints202308.0173.v1

2023

DOI: 10.20944/preprints202308.0173.v1

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A Review on the Metal Additive Manufacturing Processes

Mohaddeseh Tebianian,

Sara Aghaie,

Nazanin Sadat Razavi Jafari

et al.

Abstract: In this article, metallic additive manufacturing (AM) processes were classified and demonstrated. AM technology can be applied to a wide range of industrial areas because of its great feasibility in the design and manufacturing of various complex parts. The main factor that distinguishes various metallic AM processes from each other is the deposition method. Deposited metal can be imported in the form of melt or semi-solid. AM technology also covers a wide range of materials like aluminum, titanium, and many o… Show more

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Cited by 6 publications

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Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing

Abuabiah,

Weidemann,

Elahi

et al. 2024

JMMP

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Laser wire-feed metal additive manufacturing (LWAM) is an innovative technology that shows many advantages compared with traditional manufacturing approaches. Despite these advantages, its industrial adoption is limited by complex parameter management and inconsistent process quality. To address these issues and improve geometric accuracy, this study explores how process parameters influence bead geometry. We conducted a parameter study varying laser power, wire feed rate, traverse speed, and welding angle. Using a full factorial design with a central composite design methodology, we assessed bead height and width. This allowed us to develop a model to estimate ideal process parameters. The findings offer a detailed analysis of parameter interactions and their effects on bead geometry, aiming to enhance geometric accuracy and process stability in LWAM. Moreover, we have evaluated the proposed process parameters from our developed model, which showed a significant enhancement to the overall quality. This was validated via printing a single layer and multi-layer structures. The quality of the final predicted sample using the proposed method was improved by 40% compared to the best sample produced for the Design of Experiment trials.

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Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing

Abuabiah,

Weidemann,

Elahi

et al. 2024

JMMP

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Development of a Novel Water Jet Polisher Using Soft Abrasives for Small Complex-Structure Heat Pipes of Aluminum Alloy Produced Using Additive Manufacturing

Zhang,

Feng

et al. 2024

Materials

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It is a challenge to polish the interior surface of a small bent pipe with complex structures and sizes less than 0.5 mm. This is because of the fact that traditional polishing methods could destroy, block, or break the small complex structures. For a small bent pipe made of aluminum alloy produced using additive manufacturing, the defects, such as adhered powders and spatters, are easy to jam the pipe without polishing, possibly resulting in catastrophic failure for aerospace applications. To overcome this challenge, a novel water jet polisher was developed using soft polymethyl methacrylate (PMMA) abrasives. After polishing a specific area, the adhered powders on the interior surface were reduced from over 140 to 2, 3, and 6 by the soft abrasives with mesh sizes of 200, 400, and 600, respectively. The surface roughness Sa was decreased from 3.41 to 0.92 μm after polishing using PMMA abrasives with a mesh size of 200. In comparison, silica abrasives were also employed to polish the small bent pipes, leading to the bent part of pipes breaking. However, this kind of failure was absent when using soft abrasives. Computational fluid dynamics calculations elucidate that a peak erosion rate of silica abrasives for a bent pipe with a turn angle of 30° is 2.18 kg/(m2·s), which is 17 times that of soft abrasives. This is why the small bent pipe was broken using silica abrasives, whereas it remained intact when polished with soft abrasives. In addition, water jet polishing has a lower erosion rate, a relatively smooth erosion curve, and less erosion energy, leaving the bent parts intact. The developed soft abrasive water jet polisher and the findings of this study suggest new possibilities for cleaning the adhered powders and spatters and polishing the interior surface of small bent pipes with complex structures.

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Effects of Shot Peening and Electropolishing Treatment on the Properties of Additively and Conventionally Manufactured Ti6Al4V Alloy: A Review

Okuniewski,

Walczak,

Szala

2024

Materials

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This literature review indicates that the basic microstructure of Ti6Al4V is bimodal, consisting of two phases, namely α + β, and it occurs after fabrication using conventional methods such as casting, plastic forming or machining processes. The fabrication of components via an additive manufacturing process significantly changes the microstructure and properties of Ti6Al4V. Due to the rapid heat exchange during heat treatment, the bimodal microstructure transforms into a lamellar microstructure, which consists of two phases: α′ + β. Despite the application of optimum printing parameters, 3D printed products exhibit typical surface defects and discontinuities, and in turn, surface finishing using shot peening is recommended. A literature review signalizes that shot peening and electropolishing processes positively impact the corrosion behavior, the mechanical properties and the condition of the surface layer of conventionally manufactured titanium alloy. On the other hand, there is a lack of studies combining shot peening and electropolishing in one hybrid process for additively manufactured titanium alloys, which could synthesize the benefits of both processes. Therefore, this review paper clarifies the effects of shot peening and electropolishing treatment on the properties of both additively and conventionally manufactured Ti6Al4V alloys and shows the effect process on the microstructure and properties of Ti6Al4V titanium alloy.

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A Review on the Metal Additive Manufacturing Processes

Cited by 6 publications

References 58 publications

Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing

Investigating the Impact of Process Parameters on Bead Geometry in Laser Wire-Feed Metal Additive Manufacturing

Development of a Novel Water Jet Polisher Using Soft Abrasives for Small Complex-Structure Heat Pipes of Aluminum Alloy Produced Using Additive Manufacturing

Effects of Shot Peening and Electropolishing Treatment on the Properties of Additively and Conventionally Manufactured Ti6Al4V Alloy: A Review

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