Additive manufacturing of intricate lattice materials: Ensuring robust strut additive continuity to realize the design potential

Zhang, X.Z.; Tang, Huiping; Wang, J.; Jia, Lei; Fan, Yongtian; Leary, Martin; Qian, Ma

doi:10.1016/j.addma.2022.103022

Cited by 6 publications

(3 citation statements)

References 39 publications

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“…One of the primary advantages of L-PBF is its unparalleled design flexibility. Engineers and designers can generate intricate designs by utilizing L-PBF, which may pose challenges or even render them unattainable when employing traditional manufacturing methods [98]. The ability to modify the design allows for the creation of components that exhibit enhanced functionality, reduced mass, and improved overall performance [99].…”

Section: Advantages and Challenges Of L-pbfmentioning

confidence: 99%

A Comprehensive Review on Sustainability and Environmental Impact of Laser Powder Bed Fusion Additively Manufactured As-Built Ti-6Al-4V Parts

TUR

2023

ECJSE

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Utilization of additive manufacturing, particularly Laser Powder Bed Fusion (L-PBF), has garnered considerable interest in recent times owing to its capacity to produce intricate geometries and functional components possessing enhanced mechanical characteristics. This review provides a thorough examination of the sustainability and environmental implications associated with the production of as-built Ti-6Al-4V parts using Laser Powder Bed Fusion (L-PBF) technology in additive manufacturing. This study aims to assess the sustainability dimensions of Laser Powder Bed Fusion technology, specifically in relation to material efficiency, energy usage, and waste production. Furthermore, this study evaluates the environmental ramifications associated with L-PBF Ti-6Al-4V components across their entire life cycle, encompassing activities such as extraction of raw materials, processing, utilization, and end-of-life management. This review critically examines the existing body of knowledge pertaining to the sustainability and environmental implications associated with as-built L-PBF Ti-6Al-4V components. The objective of this study is to determine the primary factors that impact sustainability, offer a comprehensive understanding of the environmental consequences associated with L-PBF technology, and delineate the existing constraints, difficulties, and prospects for future investigations in the domain of sustainable additive manufacturing.

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Section: Advantages and Challenges Of L-pbfmentioning

confidence: 99%

A Comprehensive Review on Sustainability and Environmental Impact of Laser Powder Bed Fusion Additively Manufactured As-Built Ti-6Al-4V Parts

TUR

2023

ECJSE

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“…The extension of rapid prototyping to metallic materials through processes such as laser powder bed fusion (L-PBF), electron beam melting (EBM), and direct energy deposition (DED) has resulted in a significant increase in the usage All authors contributed equally to this work. duction of mechanical components characterized by complex geometries, which may not be obtainable through standard manufacturing techniques (as in the case of lattice structures [6][7][8][9][10][11][12][13]). In addition, the mechanical performances of additively manufactured components are comparable or superior to the analog obtained through traditional processes [14].…”

Section: Introductionmentioning

confidence: 99%

Impact of process parameters on the dynamic behavior of Inconel 718 fabricated via laser powder bed fusion

Abruzzo,

Macoretta,

Monelli

et al. 2024

Int J Adv Manuf Technol

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In this research, we investigate the dynamic behavior of Inconel 718 fabricated through laser powder bed fusion (L-PBF), addressing a notable knowledge gap regarding the correlation between process parameters and dynamic properties. The process parameters adopted are deducted from an extension of the Rosenthal solution, formulated to increase the process productivity while avoiding the typical production process defects. The dynamic Young modulus and the structural damping of the material are estimated as a function of the process parameters through ping tests reproducing the flexural vibrations of the specimens in as-built, solutioned, and aged conditions. The microstructure and porosity are investigated through metallographic analyses. The results show a substantial influence of the L-PBF process parameters on the dynamic Young modulus, which markedly increases as the energy density is reduced (23%) and progressively becomes more similar to the conventionally produced material. This influence stands in stark contrast to the relatively modest impact of heat treatments, which underlines a negligible effect of the process-induced residual stress. The structural damping remained approximately constant across all test conditions. The elastic response of the material is found to be primarily influenced by the different microstructures produced as the L-PBF process parameters varied, particularly in terms of the dimensions and shape of the solidification structures. The unexpected relationship between the dynamic Young modulus, energy density, and microstructure unveils the potential to fine-tune the material’s dynamic behavior by manipulating the process parameters, thereby carrying substantial implications for all the applications of additively manufactured components susceptible to significant vibratory phenomena.

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“…Additive manufacturing (AM) has recently highlighted to design structures and develop materials with satisfying customized properties. 9,10) Maskery et al 11) fabricated triply periodic minimal surfaces structures by additive manufacturing, and revealed that primitive and diamond structure showed superior elastic properties. Xiaofei et al 12) suggested a lattice structure modified from the rhombic dodecahedron of STS316L by LPBF showing strain rate sensitivity with increasing loading rate.…”

Section: Introductionmentioning

confidence: 99%

Deformation and Fracture Behaviors of Heterostructured STS316L/Inconel 718 by Laser Powder Bed Fusion

et al. 2023

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The current study utilized a two-step laser power bed fusion (LPBF) method to create a heterostructured material (HSM) composed of STS316L and Inconel 718. STS316L enhances ductility, while Inconel 718 improves strength. We examined the tensile deformation behavior of HSMs and found that stress is mainly localized in the cell or grain boundary area. The volumetric ratio of Inconel 718 to STS316L in the HSM affects the tensile properties, although the structural design is crucial for improving tensile strength. Fractographic analysis revealed that fracture occurred and propagated at the STS316L and Inconel 718 interface, with evident unmelted powders due to insufficient energy density. Achieving an optimized process parameter is necessary to ensure a reliable chemical joining which increases the mechanical properties of HSM.

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Additive manufacturing of intricate lattice materials: Ensuring robust strut additive continuity to realize the design potential

Cited by 6 publications

References 39 publications

A Comprehensive Review on Sustainability and Environmental Impact of Laser Powder Bed Fusion Additively Manufactured As-Built Ti-6Al-4V Parts

A Comprehensive Review on Sustainability and Environmental Impact of Laser Powder Bed Fusion Additively Manufactured As-Built Ti-6Al-4V Parts

Impact of process parameters on the dynamic behavior of Inconel 718 fabricated via laser powder bed fusion

Deformation and Fracture Behaviors of Heterostructured STS316L/Inconel 718 by Laser Powder Bed Fusion

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