Assessing the capability of in-situ nondestructive analysis during layer based additive manufacture

Hirsch, M.; Patel, Rikesh; Li, Wenqi; Guan, Guangying; Leach, Richard; Sharples, S. D.; Clare, Adam T.

doi:10.1016/j.addma.2016.10.004

Cited by 42 publications

(17 citation statements)

References 18 publications

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“…In recent years, much research has been going in this direction. The online analysis outlined assumes that non-destructive evaluation (NDE) measurements can be conducted during the manufacturing process and process measurement data on-the-fly, reducing the bottleneck apparent in the layer completion time [71]. Figure 6 depicts a flowchart of the necessary steps that have been discussed above for the realization of components that can be qualified by an industry that use PBF processes.…”

Section: Post-processingmentioning

confidence: 99%

A Metal Powder Bed Fusion Process in Industry: Qualification Considerations

2019

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An additive manufacturing process should produce repeatable results as far as the properties of the material and the geometric dimensions that have to be adopted by a company as a production method are concerned. This represents a challenge for such high-volume sectors as the automotive industry, where quality and reliability are extremely important. One way of addressing this challenge is to qualify the process. A common framework has here been identified starting from the analysis of the factors that influence the stability of the result in the main phases of metal powder bed fusion (PBF) processes. A qualification procedure (QP), which offers possible solutions to help reduce risk factors, has been proposed. This procedure is independent of the industrial sectors, of which type of materials and metal PBF processes, and of the manufacturer of the used PBF system.

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Section: Post-processingmentioning

confidence: 99%

A Metal Powder Bed Fusion Process in Industry: Qualification Considerations

2019

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“…Methods that have been developed or adapted for use with SLM/DMLS can be categorized as shown in Figure 9. Craeghs et al [97][98][99][100], Kleszczynski et al [118], Clijsters et al [119], Chivel [120], Grasso et al [121], Hirsh et al [122], Kanko et al [123], and Lott et al [124]. Infrared thermography systems for SLM/DMSL have been developed by Rodriguez et al [125] and Smurov et al [126].…”

Section: Experiments Developmentmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

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A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

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“…Optical methods are the easiest to use during experimentation, as they are usually non-disruptive to the process and can be applied externally without modifying the process or equipment. A number of excellent optimal monitoring systems has been developed, in particular those by Craeghs et al [98][99][100][101], Kleszczynski et al [119], Clijsters et al [120], Chivel [121], Grasso et al [122], Hirsh et al [123], Kanko et al [124] and Lott et al [125]. Infrared thermography systems for SLM/DMSL have been developed by Rodriguez et al [126] and Smurov et al [127].…”

Section: Optical Process Monitoringmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

2017

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Abstract:A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of the literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging and design-of-experiments), support structure optimization and overhang feature design; approximately 143 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs and potential future research directions are discussed in-depth in light of the present review.

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Assessing the capability of in-situ nondestructive analysis during layer based additive manufacture

Cited by 42 publications

References 18 publications

A Metal Powder Bed Fusion Process in Industry: Qualification Considerations

A Metal Powder Bed Fusion Process in Industry: Qualification Considerations

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

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