Net-shape manufacturing using hybrid selective laser melting/hot isostatic pressing

Abstract

Purpose: A manufacturing technology using hybrid Selective Laser Melting / Hot Isostatic Pressing (SLM/HIP) process has been developed to produce full density net-shape components more rapidly and at lower cost than processing by SLM alone.Design/methodology/approach: Ti-6Al-4V powder was encapsulated in-situ by the production of as-SLMed shell prior to the HIP process. After HIPping, the SLM shell is an integral part of the final component. Finite element modelling (FE) based on pure plasticity theory of porous metal coupled with an iterative procedure has been adopted to simulateHIPping of the encapsulated Ti-6Al-4V powder and SLMed shell. Two demonstrator parts have been modelled, designed, produced and experimentally validated. Geometrical analysis and microstructural characterisation have been carried out to demonstrate the efficiency of the process.Findings: the FE model is in agreement with the measured data obtained and confirms that the design of the shell affects the resulting deformed parts. In addition, the SEM and EBSD of the interior and exterior parts reveal a considerably different grain structure and crystallographic orientation with a good bonding between the SLMed shell and HIPped powder.Originality/value: An approach to improve SLM productivity by combining it with HIP is developed to further innovate the advanced manufacturing field. The possibility of the hybrid SLS/HIP supported by FEA simulation as a net shape manufacturing process for fabrication of high performance parts has been demonstrated

Additive Manufacturing of Porous Structures for Unmanned Aerial Vehicles Applications

“…After introducing infill porosity into the topology optimised part, FEA calculations is carried out to investigate the consequences of using porous infill in the resultant part. in agreement with previous studies that concluded the anisotropic properties of FDM samples [40][41][42] . The data shown in Figure 6 and Table 1 were used to the following simulation.…”

Porosity control in 316L stainless steel using cold and hot isostatic pressing

“…Nonetheless, residual contaminations and impurities after consolidation restrict the use of this method in biomedical implants, where the use of alloys with extra low interstitials powders is typically sought. Additive manufacturing, freeze casting and injection moulding were also investigated in the production of structures with porosity ranging 55 %-86% [11][12][13].…”

Determinants of the surface quality, density and dimensional correctness in selective laser melting of the Ti-13Zr-13Nb alloy

“…For the Ti-6Al-4V alloy, the selective laser melting (SLM) and 5-axis CNC milling were joined to produce aerospace parts from titanium powder with lower wastage [16]. The SLM was also combined with hot isostatic pressing (HIPS) to manufacture the Ti-6Al-4V alloy [17].…”