Is Laser Additive Manufacturing Sustainable?

Paul, C.P.; Yadav, Sunil; Nayak, S. K.; Jinoop, A. N.; Bindra, K. S.

doi:10.1007/978-3-030-75235-4_3

Cited by 2 publications

(6 citation statements)

References 59 publications

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“…LBAM enables digital production route with proof-of-concept designs, build planning, and simulation to optimize time, raw material, energy consumption. LBAM can create end-use parts directly from virtual data without the need of intermediate steps, improving development time and efficiency [40,53,77]. LBAM facilitates the integration of digital technologies in manufacturing processes by enabling the creation of complex geometries and parts with high precision.…”

Section: Benefits and Challenges Of Am For High-performance Metalsmentioning

confidence: 99%

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Enhancing industry 5.0 goals through laser based additively Manufactured High-Performance Metals

Nyamekye,

Westman,

Tepponen

2023

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

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In the current industry 4.0 (I4.0) and emerging Industry 5.0 (I5.0) eras, the integration of digitalization and sustainable goals is driving nature-centric and human-centric products. The production of these products are also creating digital supply chain that boosts agility and resiliency in operations, management, and supply chain interlinks. Additive manufacturing (AM), an element of I4.0, for instance, offers an integrated connection of all process steps and value chains using computer-based designing, data-driven simulations, cloud-based processing, storing, and managing software along seamless digital threads to create agile and resilient supply chain. The integration of AM and other I4.0 technologies enables greater flexibility offering intrinsic sustainable, human-centric and resilience advantages. Laser based additive manufacturing (LBAM), one of the subcategories of AM, offers opportunities to manufacture new intricate and conventionally impractical metal product designs in an ecological and economic competitive stance. High performance metals (HPMs) suited for high-stress and corrosive demanding applications are tough to machine and prone to thermal cracking in case of welding. Conventionally difficult and lengthy to manufacture yet unavoidable HPMs such as nickel alloys and titanium alloys are effortlessly possible via LBAM. Different industrial sectors that utilize these grades of metal alloys continue to adopt AM for the offered design flexibility for achieving goals such as customization, lightweight, on-demand manufacturing, raw material efficiency and cost saving. This study uses literature review and manufacturing case studies to demonstrate the flexibility and digital nature of LBAM towards I5.0 goals. The study objectively highlights the promising responsiveness of AM in the eventuality of supply disruptions that may be caused by sudden changes. The novelty of the study lies in the pragmatic emphasis on the potentials of LBAM and paired I4.0 technologies in revolutionizing the industry towards industry 5.0 goals. The study shows how I4.0 elements can be paired to enable operational efficiencies, lower carbon emissions, and foster sustainability in promoting I5.0 transformation. This study offers a fundamental understanding of the role of LBAM in the advancement of sustainability, human-centricity, and resilience.

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Section: Benefits and Challenges Of Am For High-performance Metalsmentioning

confidence: 99%

“…This is possible through the accuracy and high precision of lasers and flexibility for layerwise manufacturing for a wide range of material. LBAM also omits traditional manufacturing constraints [40,41].…”

Section: Introductionmentioning

confidence: 99%

Enhancing industry 5.0 goals through laser based additively Manufactured High-Performance Metals

Nyamekye,

Westman,

Tepponen

2023

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

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“…Laser additive manufacturing (LAM) is a significant subset of additive manufacturing (AM) technologies that plays a pivotal role in creating components with minimal material wastage, thereby contributing to sustainability efforts [1]. The sustainability aspect of LAM comes from the fabrication methodology, which uses the digital data of a part to selectively add the material as per the required geometry using layer-wise building methodology.…”

Section: Introductionmentioning

confidence: 99%

“…LPBF finds application in building highly complex parts using fine powders and lasers with beam diameters in micron scale. Out of the two LAM techniques, LDED is used for building multi-material components due to its uniqueness in a combination of material and shape design freedom [1,2]. In addition, conventional methods employed for achieving spatial variations in compositions or structures include power metallurgy, vapor deposition, centrifugal casting, and welding.…”

Section: Introductionmentioning

confidence: 99%

“…In addition, conventional methods employed for achieving spatial variations in compositions or structures include power metallurgy, vapor deposition, centrifugal casting, and welding. These traditional techniques are associated with challenges such as slower production rates, lower bond strength, limited geometrical complexity, and restricted material versatility [1]. LDED accomplishes this multi-material capacity through two significant approaches.…”

Section: Introductionmentioning

confidence: 99%

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Effect of Interlayer Composition on the Properties of Laser-Directed-Energy-Deposition-Based Additively Manufactured Copper-Stainless Steel Wall Structures

Yadav,

Paul,

Rai

et al. 2024

Sustainability

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Laser-directed energy deposition (LDED) is one of the advanced techniques used for the sustainable manufacturing of engineering components with minimal material wastage and higher performance. This paper reports an investigation on LDED-based additive manufacturing of compositionally graded Copper (Cu)-stainless steel (SS) wall structures for improved performance of tooling components. Three different approaches, such as Cu-SS direct joint, 20% graded Cu-SS, and 50% graded Cu-SS, are used to build the wall structures. Optical microscopy of LDED-built graded samples reveals defect-free deposition of Cu-SS direct joint and 50% graded Cu-SS wall structures at identified process parameters, whereas the 20%-graded wall yields micro-cracks in the lower Cu region. The elemental distribution shows gradual traditions in the weight percentages of Cu and Fe along the built wall. Furthermore, the ultimate tensile strengths of the direct Cu-SS joint wall structure and the 50%-graded Cu-SS wall structure are higher than the strength of LDED-deposited Cu, while the 20%-graded Cu-SS wall structure has lower ultimate tensile strength than the strength of LDED-deposited Cu. Lower ultimate strength and failure in the lower-Cu zone of 20% graded Cu-SS wall structure can be attributed to the presence of micro-cracks in the Cu20SS80 zone of 20%-graded Cu-SS wall structures. The study establishes LDED as a technique for building multi-material components promoting sustainability in terms of manufacturing and component performance.

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Is Laser Additive Manufacturing Sustainable?

Cited by 2 publications

References 59 publications

Enhancing industry 5.0 goals through laser based additively Manufactured High-Performance Metals

Enhancing industry 5.0 goals through laser based additively Manufactured High-Performance Metals

Effect of Interlayer Composition on the Properties of Laser-Directed-Energy-Deposition-Based Additively Manufactured Copper-Stainless Steel Wall Structures

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