Defects in Metal Additive Manufacturing Processes

Brennan, Marissa; Keist, Jayme S.; Palmer, Todd

doi:10.1007/s11665-021-05919-6

Cited by 137 publications

(41 citation statements)

References 69 publications

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“…Despite the advantages of AM versus SM mentioned above, AM has been characterized as a low-volume production system unable to date to compete against SM, with quality defects associated with component repeatability, dimensional variations, and depending on the process, lack resistance to extreme operating conditions, such as temperature, compressive, tensile, torsional and bending stresses [20][21][22].…”

Section: Additive Manufacturingmentioning

confidence: 99%

Structural and Dimensional Analysis by Computed Tomography of Multi Geometric Template Manufactured by Fused Deposition Modeling

Aguilar-Duque¹,

Ontiveros²,

Báez-López³

et al. 2023

Preprint

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During the last decade of the 20th century, there has been significant growth in the applications and development of manufacturing processes associated with Additive Manufacturing (AM). The evolution of production systems has made it possible that today there are more than 20 technologies associated with this production system. As a consequence of the development of AM, strategies have been developed to optimize the printing process focused on reducing manufacturing time, such as using Genetic Algorithms (GA). The effect caused by the modification of the path patterns is an effect of interest in two aspects; on the one hand, the dimensional assurance focused on the compliance of the dimensions of the components in comparison with the digital design of the same, and on the other hand, the structural composition and resistance that the printing process itself can generate. This paper aims to present the effect of optimizing the path of Fused Filament Fabrication (FFF) equipment on the dimensional finish and structural quality of a multi-geometric component. For this purpose, a template composed of 23 geometric elements, printed by FFF technology, using PLA as base material, is used. The dimensional analysis is performed using Geomagic software, and the porosity analysis is performed using VG Studio software concerning the 134 attributes of interest. The results show, on the one hand, a 12% reduction in the total process time required to print the component. On the other hand, using Computed Tomography (CT), it was identified the effect on the dimensional precision of printing three elements with characteristics associated with the angular precision or definition of external angles and the roundness demanded by an unsupported cantilevered arch. In addition, it was possible to ensure that the structural quality of the multi-geometric component was not affected by the modification of the path required by the printing process.

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Section: Additive Manufacturingmentioning

confidence: 99%

Structural and Dimensional Analysis by Computed Tomography of Multi Geometric Template Manufactured by Fused Deposition Modeling

Aguilar-Duque¹,

Ontiveros²,

Báez-López³

et al. 2023

Preprint

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“…Figure 8 illustrates the morphology of cracks and holes in order to provide a better understanding of these phenomena. Based on the FESEM results, it is obvious that the semi-arc crack in the coating is typical of liquefaction cracks, which are formed when the eutectic at the grain boundary is remelted during the laser cladding process, resulting in inner granular cracking related to shrinkage, and finally bending and expanding [43,44]. The hole in the coating is caused by the poor adhesion between excessive WC particles and the CoCrFeNi HEACC, which causes the particles to fall off during the metallographic preparation process.…”

Section: Phase Composition and Microstructure Featurementioning

confidence: 99%

Effects of WC on the Microstructure, Wear and Corrosion Resistance of Laser-Deposited CoCrFeNi High Entropy Alloy Coatings

Chen

Lin

et al. 2022

Coatings

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Wear and corrosion resistant properties of high entropy alloy coatings (HEAC) on H13 steel are of particular interest for industrial applications. The CoCrFeNi HEA/WC composite coatings (HEACC) developed in this study were successfully prepared by incorporating 10–40 wt.% WC into a matrix of CoCrFeNi HEA using laser cladding on an H13 steel substrate. Phase transformation, microstructure evolution, microhardness, wear and corrosion resistance of CoCrFeNi HEACC were investigated. According to the results, all CoCrFeNi HEACC exhibited higher wear and corrosion resistance than the H13 steel substrate. Wear resistance of CoCrFeNi HEACC first increases and then decreases with an increase in the concentration of WC particles, and the lowest coefficient of friction and the shallowest depth of wear groove were observed after adding 30 wt.%. Grain refinement strengthening and second-phase particle strengthening may contribute to enhanced hardness and wear resistance of coatings with WC additions. In addition, all the CoCrFeNi HEACC exhibited improved corrosion resistance. In particular, an addition of 10 wt.% WC helped to significantly improve the corrosion resistance and ease of passivation of CoCrFeNi HEACC.

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“…Surface porosity is essential for applica-FIGURE 8. L-DED 17-4PH stainless steel LOF, surface-connected porosity, and gas-entrapped pores (Brennan et al 2021) tions that require strong adhesion to other developing materials, such as those used in medical implants. Pore is important for implants because it helps in connecting and properly attaching the implants to human tissues.…”

Section: Surface-associated Porositymentioning

confidence: 99%

“…Figure 8 shows an example of surface-bonded porosity. The figure is a photomicrograph of 17-4PH stainless steel machined by DED with visible LOF and confined pores (Brennan et al 2021).…”

Section: Surface-associated Porositymentioning

confidence: 99%

Defect and Distortion in Powder Bed Fusion of Metal Additive Manufacturing Parts

Maurya

Kumar

2022

AJSTD

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One of the state-of-the-art technologies for metal fabrication is laser powder bed fusion, which includes the following printing techniques: selective laser melting, selective laser sintering, direct metal laser sintering, and electron beam melting. This work examines defect formation in laser powder bed fusion, predominately focusing on selective laser melting. It also explores recent research findings on defect formation and classification and analyzes various internal defects, such as porosity, lack of fusion, balling, and solidification cracking. The influence of process parameters on defect formation and the effect of defects on mechanical properties are analyzed. This review also discusses defect inspection technologies (melt pool, scan path, and slice monitoring), defect mitigation strategies (online detection, process parameters, and numerical simulation), and their applications in additive manufacturing, such as laser powder bed fusion. This review would aid manufacturers in determining the root cause of defect formation and developing inspection technologies and mitigation strategies.

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Defects in Metal Additive Manufacturing Processes

Cited by 137 publications

References 69 publications

Structural and Dimensional Analysis by Computed Tomography of Multi Geometric Template Manufactured by Fused Deposition Modeling

Structural and Dimensional Analysis by Computed Tomography of Multi Geometric Template Manufactured by Fused Deposition Modeling

Effects of WC on the Microstructure, Wear and Corrosion Resistance of Laser-Deposited CoCrFeNi High Entropy Alloy Coatings

Defect and Distortion in Powder Bed Fusion of Metal Additive Manufacturing Parts

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