Phenomenological modelling of direct laser metal deposition for single tracks

Mazzarisi, Marco; Campanelli, Sabina Luisa; Angelastro, Andrea; Dassisti, Michele

doi:10.1007/s00170-020-06204-x

Cited by 23 publications

(16 citation statements)

References 37 publications

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“…The liquid-based methods mostly include material jetting (MJ) and vat-based printing such as stereolithography (SLA) and digital light processing (DLP). We refer to these excellent review articles to get a comprehensive insight into the above-mentioned AM techniques, LOM [ 44 , 45 , 46 ], FDM [ 47 , 48 , 49 , 50 , 51 , 52 ], WAAM [ 53 , 54 ], EBF3 [ 55 ], SLS [ 56 , 57 ], EBM [ 58 , 59 ], SLM [ 39 , 59 , 60 ], LMD [ 61 , 62 ], SLA [ 63 , 64 , 65 ], DLP [ 66 , 67 , 68 ], and MJ [ 69 , 70 , 71 ].…”

Section: Introductionmentioning

confidence: 99%

“…The liquid-based methods mostly include material jetting (MJ) and vat-based printing such as stereolithography (SLA) and digital light processing (DLP). We refer to these excellent review articles to get a comprehensive insight into the above-mentioned AM techniques, LOM [44][45][46], FDM [47][48][49][50][51][52], WAAM [53,54], EBF3 [55], SLS [56,57], EBM [58,59], SLM [39,59,60], LMD [61,62], SLA [63][64][65], DLP [66][67][68], and MJ [69][70][71]. A polymer is a substance or material consisting of very large molecules, or macromolecules, composed of many repeating subunits [73].…”

Section: Introductionmentioning

confidence: 99%

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3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

et al. 2021

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Additive manufacturing (AM) or 3D printing is a digital manufacturing process and offers virtually limitless opportunities to develop structures/objects by tailoring material composition, processing conditions, and geometry technically at every point in an object. In this review, we present three different early adopted, however, widely used, polymer-based 3D printing processes; fused deposition modelling (FDM), selective laser sintering (SLS), and stereolithography (SLA) to create polymeric parts. The main aim of this review is to offer a comparative overview by correlating polymer material-process-properties for three different 3D printing techniques. Moreover, the advanced material-process requirements towards 4D printing via these print methods taking an example of magneto-active polymers is covered. Overall, this review highlights different aspects of these printing methods and serves as a guide to select a suitable print material and 3D print technique for the targeted polymeric material-based applications and also discusses the implementation practices towards 4D printing of polymer-based systems with a current state-of-the-art approach.

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Section: Introductionmentioning

confidence: 99%

“…The liquid-based methods mostly include material jetting (MJ) and vat-based printing such as stereolithography (SLA) and digital light processing (DLP). We refer to these excellent review articles to get a comprehensive insight into the above-mentioned AM techniques, LOM [44][45][46], FDM [47][48][49][50][51][52], WAAM [53,54], EBF3 [55], SLS [56,57], EBM [58,59], SLM [39,59,60], LMD [61,62], SLA [63][64][65], DLP [66][67][68], and MJ [69][70][71]. A polymer is a substance or material consisting of very large molecules, or macromolecules, composed of many repeating subunits [73].…”

Section: Introductionmentioning

confidence: 99%

3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

et al. 2021

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“…Single-track depositions are the basis of the most complex deposition patterns, and their analysis is crucial for the DLMD process. The main process parameters used for the deposition test were chosen basing on a previous work on the feasibility of DLMD [61], which explored different materials and setups, and are shown in Table 2.…”

Section: Test Case: Materials and Methodsmentioning

confidence: 99%

A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

Selicati

Mazzarisi

Lovecchio

et al. 2021

Int J Adv Manuf Technol

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With the constant increase of energy costs and environmental impacts, improving the process efficiency is considered a priority issue for the manufacturing field. A wide knowledge about materials, energy, machinery, and auxiliary equipment is required in order to optimize the overall performance of manufacturing processes. Sustainability needs to be assessed in order to find an optimal compromise between technical quality of products and environmental compatibility of processes. In this new Industry 4.0 era, innovative manufacturing technologies, as the additive manufacturing, are taking a predominant role. The aim of this work is to give an insight into how thermodynamic laws contribute at the same time to improve energy efficiency of manufacturing resources and to provide a methodological support to move towards a smart and sustainable additive process. In this context, a fundamental step is the proper design of a sensing and real-time monitoring framework of an additive manufacturing process. This framework should be based on an accurate modelling of the physical phenomena and technological aspects of the considered process, taking into account all the sustainability requirements. To this end, a thermodynamic model for the direct laser metal deposition (DLMD) process was proposed as a test case. Finally, an exergetic analysis was conducted on a prototype DLMD system to validate the effectiveness of an ad-hoc monitoring system and highlight the limitations of this process. What emerged is that the proposed framework provided significant advantages, since it represents a valuable approach for finding suitable process management strategies to identify sustainable solutions for innovative manufacturing procedures.

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“…Additionally, it can be used to manufacture injection molds [ 4 ] for the mass production of new products. Mazzarisi et al [ 5 ] studied three main process parameters of direct laser metal deposition and suggested the best ranges of process parameters to establish the most suitable parameters for predicting the geometric characteristics of clad. The results showed that new formulations were in good agreement with the behaviors defined in the literature.…”

Section: Introductionmentioning

confidence: 99%

A Simple Method of Reducing Coolant Leakage for Direct Metal Printed Injection Mold with Conformal Cooling Channels Using General Process Parameters and Heat Treatment

Kuo

Qiu

2021

Materials

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Direct metal printing is a promising technique for manufacturing injection molds with complex conformal cooling channels from maraging steel powder, which is widely applied in automotive or aerospace industries. However, two major disadvantages of direct metal printing are the narrow process window and length of time consumed. The fabrication of high-density injection molds is frequently applied to prevent coolant leakage during the cooling stage. In this study, we propose a simple method of reducing coolant leakage for a direct-metal-printed injection mold with conformal cooling channels by combining injection mold fabrication with general process parameters, as well as solution and aging treatment (SAT). This study comprehensively investigates the microstructural evolution of the injection mold after SAT using field-emission scanning electron microscopy and energy-dispersive X-ray spectroscopy. We found that the surface hardness of the injection mold was enhanced from HV 189 to HV 546 as the Ni-Mo precipitates increased from 12.8 to 18.5%. The size of the pores was reduced significantly due to iron oxide precipitates because the relative density of the injection mold increased from 99.18 to 99.72%. The total production time of the wax injection mold without coolant leakage during the cooling stage was only 62% that of the production time of the wax injection mold fabricated with high-density process parameters. A significant savings of up to 46% of the production cost of the injection mold was obtained.

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Phenomenological modelling of direct laser metal deposition for single tracks

Cited by 23 publications

References 37 publications

3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

A Simple Method of Reducing Coolant Leakage for Direct Metal Printed Injection Mold with Conformal Cooling Channels Using General Process Parameters and Heat Treatment

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