Developing thixo-extrusion process for additive manufacturing of metals in semi-solid state

Jabbari, Amin; Abrinia, Karen

doi:10.1016/j.jmapro.2018.08.031

Cited by 21 publications

(11 citation statements)

References 28 publications

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“…The stand-off distance and the substrate speed decides the time and thereby the length of the drop until which the drop is printed as layer. Ideally in the case of fused coated deposition, the stand-off distance is kept at 1.1 times the extruder nozzle diameter 13,46 which in presented study is 1.5 mm. Therefore, the average temperature of the drop is maintained above 500°C, for the layer deposition cases.…”

Section: Resultsmentioning

confidence: 99%

Analysis of novel induction heating extruder for additive manufacturing using aluminum filament

Sharma

Pant

Jain

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Induction Heating (IH) method is gaining traction in the field of Additive Manufacturing (AM) as it is a low cost, clean, safe, and precise energy source. Wire as a feedstock material is highly efficient as compared to the powder form in terms of material utilization and economic viability. Thus, the combination of IH and wire feedstock delivery to additive manufacture a part has been explored on an in-house developed novel AM setup. The processing of aluminum wire (Al-5356) in semi-solid form from the extruder, heated using IH method has been performed. The approach adopted in this paper is to perform an in situ infrared imaging to analyze the evolution of thermal field during the extruder heating and metal deposition process. An effective thermal cartography has been undertaken to acquire temperature history of filament, extruder, and deposition process. The temperature profile plot is utilized to understand the temperature distribution and average temperature in the heating, extrusion, and layering process during layer fabrication. The presented work facilitates a priori anticipation to utilize IH as a potential energy source for the metal AM systems.

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Section: Resultsmentioning

confidence: 99%

Analysis of novel induction heating extruder for additive manufacturing using aluminum filament

Sharma

Pant

Jain

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…The size of the nozzles is from 0.2 mm to 0.8 mm. Smaller nozzle diameter prints more precise products, but requires a longer time (Jabbari and Abrinia, 2018;Sukindar et al, 2016).…”

Section: Fused Deposition Modelling Process Parametersmentioning

confidence: 99%

An overview of fused deposition modelling (FDM): research, development and process optimisation

Dezaki

Ariffin

Hatami

2021

RPJ

100

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Purpose The purpose of this paper is to review research studies on process optimisation and machine development that lead to the enhancement of final products in various aspects of the fused deposition modelling (FDM) process. Design/methodology/approach An overview of the literature, focussing on process parameters, machine developments and material characterisations. This study investigates recent research studies that studied FDM capabilities in printing a vast range of materials from thermoplastics to metal alloys. Findings FDM is one of the most common techniques in additive manufacturing (AM) processes. Many parameters in this technology have effects on three-dimensional printed products. Therefore, it is necessary to obtain the optimum elements, for example, build orientation, layer thickness, nozzle diameter, infill pattern and bed temperature. By selecting a proper variable range of parameters, the layers adhere strongly and building end-use products of high quality are achievable. A vast range of materials and their properties from polymers to composite-based polymers are presented. Novel techniques to print metal alloys and composites are examined to increase the productivity of the FDM process. Additionally, defects such as shrinkage and warpage are discussed to eliminate the system’s limitations and improve the quality of final products. Multi-axis and mobile machines brought enhancements throughout the process to eliminate obstacles such as staircase defects in the conventional FDM process. In brief, recent developments were identified and a summary of major improvements was discussed in this study for future research. Originality/value This paper is an overview that provides information about research and developments in FDM. This review focusses on process optimisation and obstacles in printing polymers, composites, geopolymers and novel materials. Therefore, machine characteristics were examined to find out the accessibility of printing novel materials for different applications.

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“…Some authors have worked on this concept, but in all available examples, the main limitation is the melting point: alloys with a low-temperature melting point can be, with special devices, 3D printed. This process is commonly termed as semi-solid metal extrusion and deposition (SSMED) because it utilizes the extrusion of a metallic filament (for alloys like Sn-15Pb, Pb-40Sn) in a semi-solid state (thixo-extrusion) to build the 3d part [25].…”

Section: Variants Of Extrusion Techniques and Injection For Freeform ...mentioning

confidence: 99%

A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts

2019

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An extrusion based additive manufacturing (EAM) technique, recently became competitive for the rapid production of metals and ceramics components. This is made possible by extruding the metal or ceramic material in solid powder form, mixed with a binder, i.e. an expendable viscous fluid, which is removed from the part after 3D printing. The strength of these technologies relies on the large design freedom allowed by and by the cost efficiency advantage vs. alternative metal additive manufacturing processes based on high energy beams, e.g. laser/electron beam.EAM of metals and ceramics is not yet widespread, and the published scientific and technical literature is rapidly growing, but still less extensive than the literature on FDM of plastics or SLM of metals. This paper aims at filling this gap. Fused Deposition Modeling (FDM) and Powder Injection Molding (PIM) are identified as preceding or enabling technologies for EAM. This paper systematically reviews all the aspects of feedstock extrusion-based AM processes used for production of complex shaped parts. Then, the unique characteristics and advantages of the process are discussed, with respect to materials and process steps. The key process parameters are explained to illustrate the suitability of the process for diverse domains of applications.

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Developing thixo-extrusion process for additive manufacturing of metals in semi-solid state

Cited by 21 publications

References 28 publications

Analysis of novel induction heating extruder for additive manufacturing using aluminum filament

Analysis of novel induction heating extruder for additive manufacturing using aluminum filament

An overview of fused deposition modelling (FDM): research, development and process optimisation

A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts

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