Additive Manufacturing of Tungsten Carbide Hardmetal Parts by Selective Laser Melting (SLM), Selective Laser Sintering (SLS) and Binder Jet 3D Printing (BJ3DP) Techniques

Muthuswamy, Padmakumar

doi:10.1007/s40516-020-00124-0

Cited by 70 publications

(4 citation statements)

References 104 publications

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“…Experiments processed with 0.149 J/cm 2 , 52.5 kHz and 500 mm/s transferred the most amount of laser energy; they appeared burnt and had the most remelting in the region (Figure 14b, Figure 14d). This is as expected as the high fluence and frequency paired with the slower speed prolonged the amount of energy delivered-giving time for the workpiece to heat and melt but not ablate ( [15,48]). In some samples, the laser raster pattern was evidenced by material peaks and bulges of remelted material (Figure 14e).…”

Section: Effect Of Fluence and Speed On Materials Processingsupporting

confidence: 62%

Understanding the surface integrity of laser surface engineered tungsten carbide

Hazzan

Pacella

See

2021

Int J Adv Manuf Technol

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The study investigated the effect of fibre laser processing (1060 nm, 240-ns pulse duration) on the surface integrity of tungsten carbide (WC). The induced surface damage ranged from crack formation, porosity, balling, to spherical pores; the severity and presence of each were dependent on the laser parameters selected. The influence of fluence (0.05–0.20 J/cm2), frequency (5–100 kHz), feed speed (250–2500 mm/s) and hatch distance (0.02–0.06 mm) on 2D and 3D surface roughness were analysed using the Taguchi technique. Fluence, frequency, and the interaction effect of these were the most influential factors on the surface integrity; from this a linear model was generated to predict the surface roughness. The model performed best at moderate to medium level of processing with an error between 1 and 10 %. The model failed to predict the material response as accurately at higher fluences with percentage errors between 15 and 36 %. In this study, a crack classification system and crack density variable were introduced to estimate the number of cracks and crack type within a 1-mm2 area size. Statistical analysis of variance (ANOVA) found that fluence (63.49%) and frequency (29.38%) had a significant effect on the crack density independently but not the interaction of both. The crack density was minimised at 0.149 J/cm2 and 52.5 kHz. To the author’s knowledge, for the first time, a quantitative analysis of the crack formation mechanism for brittle materials is proposed (post laser processing).

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Section: Effect Of Fluence and Speed On Materials Processingsupporting

confidence: 62%

Understanding the surface integrity of laser surface engineered tungsten carbide

Hazzan

Pacella

See

2021

Int J Adv Manuf Technol

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“…The only difference is that the name FDM is a registered trademark of the Stratasys company, while the FFF has no registered trademark 7,8 . On the other hand, in the case of metals, 3D printing is typically accomplished by melting metal powders in specific areas, typically with the use of a laser 9 . All these AM techniques have the advantage of being inexpensive, fast to design, and easy to produce 10 …”

Section: Introductionmentioning

confidence: 99%

Fatigue response of auxetic structures: A review

Parente,

Reis,

Berto

2024

Fatigue Fract Eng Mat Struct

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The fatigue behavior of auxetic metamaterials is an interesting and recent research topic that will deserve future attention. How different geometries can interact with cyclic loadings is still an open question for these kinds of structures. Therefore, this review aims to provide an update on the state of the art on the fatigue response of auxetic structures, showing which research questions are open and possible future developments. As will be evident from this review, there is still room for further improvements that will allow these structures to become much more attractive for load‐bearing applications.

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“…However, MPBF is a complex manufacturing process with many processing parameters that influence the properties of the as-built part (Malekipour and El-Mounayri, 2018). Quality issues such as diversity in microstructure (Padmakumar, 2020), poor surface finish (Nurhudan et al , 2021) and inherent residual stresses (RS) (Rane, 2019) have detrimental effects on the final part quality. The existing review studies on MPBF have discussed its application with specific materials such as steels, Al-alloy, Ti-alloy, Nickel-based superalloys and Co–Cr (Haghdadi et al , 2021; Lowther et al , 2019; Revilla-León et al , 2020; Sanchez et al , 2021; Sing and Yeong, 2020); MPBF process defects and their physical phenomena such as balling, porosity, gas pores, lack of fusion regions, surface defects and RS (Bartlett and Li, 2019; Dowling et al , 2020; Maleki et al , 2021; Snow et al , 2020; Zhang et al , 2019, 2018) and effect of processing parameters on build part quality (Azarniya et al , 2019; Chahal and Taylor, 2020; Tan et al , 2020; Yusuf and Gao, 2017).…”

Section: Introductionmentioning

confidence: 99%

Review of quality issues and mitigation strategies for metal powder bed fusion

Ravalji

Raval

2022

RPJ

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Purpose Selective laser melting and electron beam melting processes are well-known for the additive manufacturing of metal parts. Metal powder bed fusion (MPBF) is a common term for them. The MPBF process can empower the manufacturing of intricate shapes by reducing the use of special tools, shortening the supply chain and allowing small batches. However, the MPBF process suffers from many quality issues. In literature, several works are recorded for qualification of the MPBF part. The purpose of this study is to recollect those works done for quality control and report their helpful findings for further research and development. Design/methodology/approach A systematic literature review was conducted to highlight the major quality issues in the MPBF process and its root causes. Further, the works reported in the literature for mitigation of these issues are classified and discussed in five categories: experimental investigation, finite element method-based numerical models, physics-based analytical models, in-situ control using artificial intelligence (AI) and machine learning (ML) methods and statistical approaches. A comparison is also prepared among these strategies based on their suitability and limitations. Additionally, improvements in MPBF printers are pointed out to enhance the part quality. Findings Analytical models require less computational time to simulate the MPBF process and need a smaller number of experiments to confirm the results. They can be used as an efficient process parameter planning tool to print metal parts for noncritical applications. The AI-ML based quality control is also suitable for MPBF processes as it can control many processing parameters that may affect the quality of the MPBF part. Moreover, capabilities of MPBF printers like thinner layer thickness, smaller beam diameter, multiple lasers and high build temperature range can help in quality control. Research limitations/implications This study converts the piecemeal data on MPBF part qualification methods into interesting information and presents it in tabular form under each strategy. This tabular information provides the basis for further quality improvement efforts in the MPBF process. Originality/value This study references researchers and practitioners on recent quality control efforts and their significant findings for a better quality of MPBF part.

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Additive Manufacturing of Tungsten Carbide Hardmetal Parts by Selective Laser Melting (SLM), Selective Laser Sintering (SLS) and Binder Jet 3D Printing (BJ3DP) Techniques

Cited by 70 publications

References 104 publications

Understanding the surface integrity of laser surface engineered tungsten carbide

Understanding the surface integrity of laser surface engineered tungsten carbide

Fatigue response of auxetic structures: A review

Review of quality issues and mitigation strategies for metal powder bed fusion

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