Metal 3D printing in construction: A review of methods, research, applications, opportunities and challenges

Buchanan, Craig; Gardner, Leroy

doi:10.1016/j.engstruct.2018.11.045

Cited by 536 publications

(303 citation statements)

References 69 publications

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“…With DED, engineered compositional and microstructural gradients in the structural parts are possible, which might give superior mechanical properties. An important thing to note is that the construction industry contributes to about 30% of greenhouse emissions in total, which could be reduced by partly adopting AM for the mass production of specialized parts [164].…”

Section: Construction Materialsmentioning

confidence: 99%

State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

2019

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Additive manufacturing (AM) is a new paradigm for the design and production of high-performance components for aerospace, medical, energy, and automotive applications. This review will exclusively cover directed energy deposition (DED)-AM, with a focus on the deposition of powder-feed based metal and alloy systems. This paper provides a comprehensive review on the classification of DED systems, process variables, process physics, modelling efforts, common defects, mechanical properties of DED parts, and quality control methods. To provide a practical framework to print different materials using DED, a process map using the linear heat input and powder feed rate as variables is constructed. Based on the process map, three different areas that are not optimized for DED are identified. These areas correspond to the formation of a lack of fusion, keyholing, and mixed mode porosity in the printed parts. In the final part of the paper, emerging applications of DED from repairing damaged parts to bulk combinatorial alloys design are discussed. This paper concludes with recommendations for future research in order to transform the technology from “form” to “function,” which can provide significant potential benefits to different industries.

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Section: Construction Materialsmentioning

confidence: 99%

State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

2019

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“…At the macro-and mesoscale (down to 100 µm), additive manufacturing (AM) of metal objects is recurrently performed with robust methods like selective laser and electron beam melting, both relying on the local fusion of metal particles to obtain a solid metal with the desired shape [1][2][3][4][5]. Typical voxel sizes are reported in the range of 100 to 400 µm [6] As alternatives, one can take into consideration the well-established localized electrochemical deposition (LED) [7,8] and laser chemical vapor deposition (LCVD) [9] methods, whose minimum feature sizes are continuously improved down to 10 µm [10,11] and correspondingly interpreted [12,13].…”

Section: Metal Additive Manufacturing At the Micro Scalementioning

confidence: 99%

Additive Manufacturing of Sub-Micron to Sub-mm Metal Structures with Hollow AFM Cantilevers

Ercolano¹,

Nisselroy

Merle³

et al. 2019

Micromachines

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We describe our force-controlled 3D printing method for layer-by-layer additive micromanufacturing (µAM) of metal microstructures. Hollow atomic force microscopy cantilevers are utilized to locally dispense metal ions in a standard 3-electrode electrochemical cell, enabling a confined electroplating reaction. The deflection feedback signal enables the live monitoring of the voxel growth and the consequent automation of the printing protocol in a layer-by-layer fashion for the fabrication of arbitrary-shaped geometries. In a second step, we investigated the effect of the free parameters (aperture diameter, applied pressure, and applied plating potential) on the voxel size, which enabled us to tune the voxel dimensions on-the-fly, as well as to produce objects spanning at least two orders of magnitude in each direction. As a concrete example, we printed two different replicas of Michelangelo’s David. Copper was used as metal, but the process can in principle be extended to all metals that are macroscopically electroplated in a standard way.

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“…Low mass and high stiffness make them attractive as engineering materials [5]. They have been started to be used in this field of application in leading branches of industry (automotive [6,7], aviation [8], railway [9], bio-engineering [10,11] and military [12][13][14]) as well as in civil engineering and modern art. Furthermore, high porosity resulted from a low value of relative density causes that they can be used as an effective thermal-, sound-and vibro-insulators [15,16].…”

Section: Introductionmentioning

confidence: 99%

Investigations on the Mechanical Response of Gradient Lattice Structures Manufactured via SLM

Sienkiewicz

Płatek

Jiang

et al. 2020

Metals

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The main aim of the paper is to evaluate the mechanical behavior or lattice specimens subjected to quasi-static and dynamic compression tests. Both regular and three different variants of SS 316L lattice structures with gradually changed topologies (discrete, increase and decrease) have been successfully designed and additively manufactured with the use of the selective laser melting technique. The fabricated structures were subjected to geometrical quality control, microstructure analysis, phase characterization and compression tests under quasi-static and dynamic loading conditions. The mismatch between dimensions in the designed and produced lattices was noticed. It generally results from the adopted technique of the manufacturing process. The microstructure and phase composition were in good agreement with typical ones after the additive manufacturing of stainless steel. Moreover, the relationship between the structure relative density and its energy absorption capacity has been defined. The value of the maximum deformation energy depends on the adopted gradient topology and reaches the highest value for a gradually decreased topology, which also indicates the highest relative density. However, the highest rate of densification was observed for a gradually increasing topology. In addition, the results show that the gradient topology of the lattice structure affects the global deformation under the loading. Both, static and dynamic loading resulted in both barrel- and waisted-shaped deformation for lattices with an increasing and a decreasing gradient, respectively. Lattice specimens with a gradually changed topology indicate specific mechanical properties, which make them attractive in terms of energy absorption applications.

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Metal 3D printing in construction: A review of methods, research, applications, opportunities and challenges

Cited by 536 publications

References 69 publications

State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

State of the Art in Directed Energy Deposition: From Additive Manufacturing to Materials Design

Additive Manufacturing of Sub-Micron to Sub-mm Metal Structures with Hollow AFM Cantilevers

Investigations on the Mechanical Response of Gradient Lattice Structures Manufactured via SLM

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