Design methodology for variable shell mould thickness and thermal conductivity additively manufactured

Néel, Tugdual Amaury Le; Mognol, Pascal; Hascoët, Jean-Yves

doi:10.1007/s40194-018-0598-2

Cited by 4 publications

(3 citation statements)

References 7 publications

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“…Product design optimization methods including lattice, topology and variable thickness can be digitally generated and fine-tuned based on design for additive manufacturing (DfAM) rules to suit specific AM subcategory prior physical commitments. Different studies have investigated how optimized structures including honeycombs, lattice, variable thickness, build plan, process parameters (mainly from material deposition, beam shapes or spots) influence functional properties, energy intensities and related costs of high-performance metals [7][8][9][10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

Optimized Inconel 718 pressure vessel manufactured with laser powder bed fusion

Tepponen,

Westman,

Nyamekye

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Laser powder bed fusion (L-PBF) is one of the most novel additive manufacturing methods used for a wide range of industrial grade metallic materials. The process can produce end-use metal parts with desirable qualities and mechanical properties. L-PBF however, remains a complicated and expensive manufacturing method. Design for additive manufacturing (DfAM) is a key aspect leveraging the uptake of advantages and possibilities offered by AM in augmenting its competitiveness against conventional manufacturing (CM) methods. Inconel 718 (IN718) is a nickel-based superalloy boasting high temperature strength, good oxidation, and corrosion resistance at elevated temperatures. IN718 is commonly used for high performance applications, such as power and process industry parts, and gas turbine components. High inherent toughness, hardness, work hardening, and low thermal conductivity properties make the material difficult to manufacture through conventional machining methods. The layer-by-layer building of powder metals via L-PBF makes it possible to build different geometrical intricacy. The offered manufacturing flexibility for complex high-end metal structures for variety of applications makes L-PBF an alternative manufacturing method for high performance metals. This study investigates use of DfAM for a small-scale pressure vessel with predefined geometry, dimensions, design space and load condition. The aim is to introduce and exploit contemporary design optimization methods and their feasibility with AM. Structures, such as lattices and stress field driven geometries based on finite element analysis are investigated in this study. The designs are virtually tested under predefined pressure load of 50 bar. All four design options are manufactured on EOS M290 and IN718 powder. The result of the study shows the different optimizations decrease weight and improve material savings without compromising the linear load capacity. Optimized designs could also be made in such a way that it does not increase the manufacturing duration or add additional steps to it.

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Section: Introductionmentioning

confidence: 99%

Optimized Inconel 718 pressure vessel manufactured with laser powder bed fusion

Tepponen,

Westman,

Nyamekye

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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“…Moreover, rapid tooling is important to the industries (Rooks, 2002) in terms of reducing prototyping cost. Today, the main companies who positioned themselves in the market of additively manufactured sand molds are Voxeljet, ExOne (Le Néel et al , 2018a) and various research works are available that are focused on binder jetting applications in sand casting using these printers (Zhao et al , 2018; Le Néel et al , 2018b). The available research studies have been focused on the influence of the following process parameters (Hodder and Chalaturnyk, 2019): analysis of the cast dimensional accuracy pouring aluminum alloys (Le Néel et al , 2018b); measuring the influence of the part/wall thickness on the part cooling time (Walker et al , 2018); leverages binder jetting technology to design a smart molds with sensor integrated to study the thermodynamics and physics of the casting process (Szymański and Borowiak, 2019); testing the effect of different sand graininess and different binder on the casted part roughness.…”

Section: Introductionmentioning

confidence: 99%

“…Today, the main companies who positioned themselves in the market of additively manufactured sand molds are Voxeljet, ExOne (Le Néel et al , 2018a) and various research works are available that are focused on binder jetting applications in sand casting using these printers (Zhao et al , 2018; Le Néel et al , 2018b). The available research studies have been focused on the influence of the following process parameters (Hodder and Chalaturnyk, 2019): analysis of the cast dimensional accuracy pouring aluminum alloys (Le Néel et al , 2018b); measuring the influence of the part/wall thickness on the part cooling time (Walker et al , 2018); leverages binder jetting technology to design a smart molds with sensor integrated to study the thermodynamics and physics of the casting process (Szymański and Borowiak, 2019); testing the effect of different sand graininess and different binder on the casted part roughness. Furthermore, several studies have been conducted on the generation of complex molds via the use of 3D printing: cellular structures have been designed to obtain complex aluminum (Snelling et al , 2015; Kim et al , 2018) and iron casts (Wang et al , 2019; Druschitz et al , 2017) or lattice-reinforced thickness-varying shell molds (Shangguan et al , 2018; Shangguan et al , 2017).…”

Section: Introductionmentioning

confidence: 99%

Casting of complex structures in aluminum using gypsum molds produced via binder jetting

Giorleo

Bonaventi

2021

RPJ

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Purpose The purpose of present paper is to enlarge the knowledge about the performance of gypsum powder to realize complex molds or cores for aluminum casting. Design/methodology/approach The research was divided into two activities: simple; and complex-part production capability. In the simple-part step, the performance of gypsum powder and the minimum mold thickness that would withstand the casting process. In the complex-part step, the authors first investigated the powder removability as a function of geometry complexity and then binder jetting performance was evaluated for the case of lattice-structure fabrication. Findings All the geometries tested withstand the casting process demonstrating the benefits in terms of complexity part design; however, the process suffers of all the typical defect of casting as misrun, porosity and cold shut. Originality/value The results found in this research improve the benefits related to additive manufacturing application in industrial environment and in particular to the binder jetting technology and the rapid casting approach.

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Integration of Additive Manufacturing in Casting: Advances, Challenges, and Prospects

Gao

Wang

et al. 2021

Int. J. of Precis. Eng. and Manuf.-Green Tech.

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Design methodology for variable shell mould thickness and thermal conductivity additively manufactured

Cited by 4 publications

References 7 publications

Optimized Inconel 718 pressure vessel manufactured with laser powder bed fusion

Optimized Inconel 718 pressure vessel manufactured with laser powder bed fusion

Casting of complex structures in aluminum using gypsum molds produced via binder jetting

Integration of Additive Manufacturing in Casting: Advances, Challenges, and Prospects

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