Justification of the Use of Composite Metal-Metal-Polymer Parts for Functional Structures

Abstract

The additive manufacturing of metal parts takes up an increasing number of areas of mechanical engineering, but it still remains too expensive for mass use. Based on the experience in the production of combined metal-metal-polymer forming parts of molds, a new method for the production of composite parts from a metal shell filled with metal-polymer is proposed. As a basis for the study, strength calculations are given by the finite element method for the details of the exoskeleton and a sample of simplified geometry. Comparison of the strength characteristics of parts made of various materials and their combinations showed high strength characteristics of a composite part made of a metal shell and a metal-polymer filler. The metal-metal polymer composite part is distinguished not only by its high strength but also by a significantly lower cost, due to the reduction in the volume of 3D printing with metal. The problems of obtaining composite structures are also discussed. The main problem is the development of a metal-polymer casting technology. The process of filling a thin-walled shell with a metal-polymer causes difficulty.

Reducing the Cost of 3D Metal Printing Using Selective Laser Melting (SLM) Technology in the Manufacture of a Drill Body by Reinforcing Thin-Walled Shell Forms with Metal-Polymers

“…Structural materials include various alloys and steels. An analysis of Table 2 and studies [28][29][30][31][32] shows that the strength characteristics of polymer composite materials are inferior to structural ones, and their anisotropy is also observed. For example, the tensile strength under compression is 5 times more than the tensile strength under tension, and the tensile strength with normal separation is 10 times less than the tensile strength under tension.…”

“…In this case, the clamping forces on opposite sides compensate themselves. This can be achieved by filling the voids with a metal polymer that has sufficient compressive strength [32,34]. Another group of surfaces that have special requirements are surfaces for mounting the cutting head (Figure 7).…”

Thermo-Mechanical Processing as Method Decreasing Delta-Ferrite and Improving the Impact Toughness of the Novel 12% Cr Steels with Low N and High B Contents

“…Equilibrium phase diagrams were evaluated via Thermo-Calc software (Version 5.0.4 75, Thermo-Calc software AB, Stockholm, Sweden, 2010). Analysis of the mechanical properties and structural characterization technique was considered in detail in [7,8,10,[18][19][20][21][31][32][33]36].…”

Overview of 3D Printed Exoskeleton Materials and Opportunities for Their AI-Based Optimization

“…Combined metal-polymer elements can be a technological breakthrough in the field of 3D-printed exoskeletons. It is all about the strength properties of the combination of the metal shell and the metal-polymer filler [18]. The design challenges include, above all, the development of a 3D-printed exoskeleton of the hand with five fingers, physiological ranges of motion, adequate strength, and possible grips [19].…”