An Overview of Additive Manufacturing Technologies—A Review to Technical Synthesis in Numerical Study of Selective Laser Melting

Abstract

Additive Manufacturing (AM) processes enable their deployment in broad applications from aerospace to art, design, and architecture. Part quality and performance are the main concerns during AM processes execution that the achievement of adequate characteristics can be guaranteed, considering a wide range of influencing factors, such as process parameters, material, environment, measurement, and operators training. Investigating the effects of not only the influential AM processes variables but also their interactions and coupled impacts are essential to process optimization which requires huge efforts to be made. Therefore, numerical simulation can be an effective tool that facilities the evaluation of the AM processes principles. Selective Laser Melting (SLM) is a widespread Powder Bed Fusion (PBF) AM process that due to its superior advantages, such as capability to print complex and highly customized components, which leads to an increasing attention paid by industries and academia. Temperature distribution and melt pool dynamics have paramount importance to be well simulated and correlated by part quality in terms of surface finish, induced residual stress and microstructure evolution during SLM. Summarizing numerical simulations of SLM in this survey is pointed out as one important research perspective as well as exploring the contribution of adopted approaches and practices. This review survey has been organized to give an overview of AM processes such as extrusion, photopolymerization, material jetting, laminated object manufacturing, and powder bed fusion. And in particular is targeted to discuss the conducted numerical simulation of SLM to illustrate a uniform picture of existing nonproprietary approaches to predict the heat transfer, melt pool behavior, microstructure and residual stresses analysis.

Application of Additively Manufactured Pentamode Metamaterials in Sodium/Inconel 718 Heat Pipes

“…With pentamode metamaterial reinforcement, elastic strains occurred not only in the heat pipe walls but also in the reinforcement, as seen in the zoomed-in images in Figure 10 . Because Poisson’s ratio of pentamode metamaterials was negative, strain areas in the reinforcement were larger than that in the heat pipe walls [ 19 , 27 , 28 ]. Therefore, stresses in the heat pipes were accommodated.…”

“…According to above analysis, it was demonstrated that pentamode metamaterial reinforcement could accommodate thermal stresses in sodium/Inconel 718 heat pipes; hence, this was a solution to the thermal-structure problems of alloys. Other potential applications (using different topological structures and different heat pipes) included: limiting thermal distortions of hot structures [ 28 ], cooling of space reactors, and thermal management of hypersonic vehicles. Recently, heat pipes with pentamode reinforcement were designed for space reactor cooling.…”

Reliability of Metal 3D Printing with Respect to the Marginal Fit of Fixed Dental Prostheses: A Systematic Review and Meta-Analysis

“…This process enables the fabrication of sophisticated customized products without complicated laboratory manual works, unlike conventional manufacturing methods [3]. Powder bed fusion is a form of a 3D printing technology commonly used for metal 3D printing [4,5]. This technology is also referred to as selective laser sintering (SLS), selective laser melting (SLM), direct metal laser sintering (DMLS), or electron beam melting (EBM) in the literature [6,7].…”

In Situ Monitoring of Additive Manufacturing Using Digital Image Correlation: A Review

“…Another technological advantage is the ability to produce parts with an almost final shape, thus reducing production time and costs [ 6 ]. Nevertheless, products obtained by AM still require further development on open issues regarding internal defects due to printing errors and residual and thermal stresses, for instance [ 7 , 8 ]. This quality uncertainty can create parts wastage, increase parts delivery time and prevent AM implementation in industries that require high performance components with quality assurance.…”