Evaluation of surface/interface quality, microstructure and mechanical properties of hybrid additive-subtractive aluminium parts

Bhaduri, Debajyoti; Penchev, Pavel; Essa, Khamis; Dimov, Stefan Simeonov; Carter, Luke N.; Pruncu, Catalin I.; Pullini, D.

doi:10.1016/j.cirp.2019.04.116

Cited by 28 publications

(15 citation statements)

References 9 publications

(15 reference statements)

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“…There are significant advances in system-level tools for integration of AM processes, e.g. powder bed fusion (PBF) technologies (Penchev et al, 2019;Boivie et al, 2011), in multi-setup HM platforms for producing hybrid components (Bhaduri et al, 2019).…”

Section: Introductionmentioning

confidence: 99%

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Mehmeti

Penchev

Lynch

et al. 2020

RPJ

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Purpose The paper reports an investigation into the mechanical behaviour of hybrid components produced by combining the capabilities of metal injection moulding (MIM) with the laser-based powder bed fusion (PBF) process to produce small series of hybrid components. The research investigates systematically the mechanical properties and the performance of the MIM/PBF interfaces in such hybrid components. Design/methodology/approach The MIM process is employed to fabricate relatively lower cost preforms in higher quantities, whereas the PBF technology is deployed to build on them sections that can be personalised, customised or functionalised to meet specific technical requirements. Findings The results are discussed, and conclusions are made about the mechanical performance of such hybrid components produced in batches and also about the production efficiency of the investigated hybrid manufacturing (HM) route. The obtained results show that the proposed HM route can produce hybrid MIM/PBF components with consistent mechanical properties and interface performance which comply with the American Society for Testing and Materials (ASTM) standards. Originality/value The manufacturing of hybrid components, especially by combining the capabilities of additive manufacturing processes with cost-effective complementary technologies, is designed to be exploited by industry because they can offer flexibility and cost advantages in producing small series of customisable products. The findings of this research will contribute to further develop the state of the art in regards to the manufacturing and optimisation of hybrid components.

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Section: Introductionmentioning

confidence: 99%

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Mehmeti

Penchev

Lynch

et al. 2020

RPJ

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“…overhangs, undercuts and part assemblies with moving components, that are then removed using a post-processing operation. However, the removal of such support structures by machining can become difficult and even impossible [78,81,82]. As a consequence, a re-design of parts can be required to eliminate or minimise the need for support structures.…”

Section: Limitations Of Powder-based Laser Additive Manufacturing Formentioning

confidence: 99%

“…The modular work holding system reported in [122] was later employed by Badhuri et al [82] to investigate the surface integrity, microstructure and mechanical properties of hybrid AM aluminium parts produced by employing LPBF followed by some machining operations. In another research, the same work holding system was deployed to build LPBF structures on top of metal injection moulded (MIM) preforms and thus Fig.…”

Section: Hybrid Additive/machining Solutionsmentioning

confidence: 99%

Powder-based laser hybrid additive manufacturing of metals: a review

Jiménez

Bidare

Hassanin

et al. 2021

Int J Adv Manuf Technol

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Recent advances in additive manufacturing (AM) have attracted significant industrial interest. Initially, AM was mainly associated with the fabrication of prototypes, but the AM advances together with the broadening range of available materials, especially for producing metallic parts, have broaden the application areas and now the technology can be used for manufacturing functional parts, too. Especially, the AM technologies enable the creation of complex and topologically optimised geometries with internal cavities that were impossible to produce with traditional manufacturing processes. However, the tight geometrical tolerances along with the strict surface integrity requirements in aerospace, biomedical and automotive industries are not achievable in most cases with standalone AM technologies. Therefore, AM parts need extensive post-processing to ensure that their surface and dimensional requirements together with their respective mechanical properties are met. In this context, it is not surprising that the integration of AM with post-processing technologies into single and multi set-up processing solutions, commonly referred to as hybrid AM, has emerged as a very attractive proposition for industry while attracting a significant R&D interest. This paper reviews the current research and technology advances associated with the hybrid AM solutions. The special focus is on hybrid AM solutions that combine the capabilities of laser-based AM for processing powders with the necessary post-process technologies for producing metal parts with required accuracy, surface integrity and material properties. Commercially available hybrid AM systems that integrate laser-based AM with post-processing technologies are also reviewed together with their key application areas. Finally, the main challenges and open issues in broadening the industrial use of hybrid AM solutions are discussed.

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“…On the other hand, Bhaduri et al [31] evaluated tensile mechanical properties and microstructure of hybrid specimens made from AlSi10Mg parts built by LPBF on AA6082 machined parts. The hybrid components failed under tension at their interface.…”

Section: Introductionmentioning

confidence: 99%

Fatigue Behavior of Hybrid Components Containing Maraging Steel Parts Produced by Laser Powder Bed Fusion

Santos

Jesús

Borrego

et al. 2021

Metals

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This investigation concerns about of fatigue behavior under controlled loading and under strain control for hybrid specimens with parts produced with conventional processes in steel AISI H13 and the stainless steel AISI 420 and the rest part produced by laser powder bed fusion in AISI 18Ni300 steel. The controlled loading tests were performed in constant and variable amplitude. Fatigue failure of hybrid samples occurs mostly in laser-melted parts, initiated around the surface, in many cases with multi-nucleation and propagated predominantly between the deposited layers. Fatigue strength of hybrid parts, tested under displacement control is similar, but for specimens tested under load control the fatigue strength the fatigue strength of hybrid specimens is progressively lesser than laser powder bed fusion samples. Despite a tendency to obtain conservative predictions, Miner’s law predicts reasonably the fatigue lives under block loadings. The interface between materials presented an excellent joining and fatigue strength because the fatigue failure of hybrid samples occurred mostly in laser melted parts out of the interface.

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Evaluation of surface/interface quality, microstructure and mechanical properties of hybrid additive-subtractive aluminium parts

Cited by 28 publications

References 9 publications

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Powder-based laser hybrid additive manufacturing of metals: a review

Fatigue Behavior of Hybrid Components Containing Maraging Steel Parts Produced by Laser Powder Bed Fusion

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