Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: a review

Bidare, Prveen; Jiménez, Amaia; Hassanin, Hany; Essa, Khamis

doi:10.1007/s40436-021-00365-y

Cited by 32 publications

(5 citation statements)

References 144 publications

(204 reference statements)

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“…This limitation is due to technical challenges from the process, including inherent porosity, incomplete sintering as post-processing and brittle properties of parts [21]. Nevertheless, despite the advantages of the repair process, the beam-based AM process also possesses several limitations, which include anisotropic mechanical properties and residual stress caused by high thermal stress and rapid solidi cation [22]. Consequently, the limitations become more critical when the beam-based AM is applied for the additive repair of the used components.…”

Section: Implementation Of Additive Repairmentioning

confidence: 99%

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Failure-based design validation for effective repair of multi-metal additive manufacturing: the case of remanufacturable brake caliper

Aziz,

Elanggoven,

Wahab

et al. 2024

Int J Adv Manuf Technol

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The inclusion of additive manufacturing (AM) as an automated repair method leads to a sustainable remanufacturing process, which is known as additive repair. Despite its potential in improving the e ciency of repair and restoration, additive repair remains in its infancy and requires a thorough investigation on part design and process parameters. The major concern raised in additive repair is the capability to create perfect bonding between two metals, which will affect the mechanical properties of the complete repaired part. Hence, performing evaluation from the beginning is crucial to validate the feasibility of the process through appropriate structural analysis and to obtain deformation and stress results. Brake caliper housing is selected as a remanufacturable component for case exemplary purposes. Prior to analysis, the potential damages and failures of the brake caliper component were initially evaluated through literature surveys and direct interviews with industry experts where two types of damages were identi ed, namely, cracks and broken or fractured parts. Then, the validation focuses on comparative analysis of three different conditions of the brake caliper housing: original, damaged and repaired caliper model using nite element analysis in ANSYS. Results indicate that the strength of the repaired caliper model shows equal and higher strength compared with the original model. This result con rms that the repair process through AM can retain or improve the quality of the remanufactured brake caliper housing. Therefore, this paper provides a systematic framework for the evaluation of mechanical properties in multi-metal additive repair with the integration of failure analysis techniques.

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Section: Implementation Of Additive Repairmentioning

confidence: 99%

“…The accuracy in each AM is highly affected by the different values of process parameters involved. Bidare et al [22] discussed the porosity, cracks and mechanical properties exerted in AM for tooling alloys. The research highlights the advantages of available AM technologies.…”

Section: Implementation Of Additive Repairmentioning

confidence: 99%

Failure-based design validation for effective repair of multi-metal additive manufacturing: the case of remanufacturable brake caliper

Aziz,

Elanggoven,

Wahab

et al. 2024

Int J Adv Manuf Technol

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show abstract

“…Additive manufactured parts may experience geometric flaws [ 115 ] due to surface defects (such as balling, high surface roughness, surface deformation, such as warping and distortion) and sub-surface defects, such as porosity [ 116 ]. Cracking, delamination on deposited material and residual stress are the thorniest issues associated with the AM technologies [ 117 ] for the SLS process, as illustrated in Figure 10 .…”

Section: Intelligence In State-of-the-art Manufacturing Technology: M...mentioning

confidence: 99%

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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Additive manufacturing (AM), an enabler of Industry 4.0, recently opened limitless possibilities in various sectors covering personal, industrial, medical, aviation and even extra-terrestrial applications. Although significant research thrust is prevalent on this topic, a detailed review covering the impact, status, and prospects of artificial intelligence (AI) in the manufacturing sector has been ignored in the literature. Therefore, this review provides comprehensive information on smart mechanisms and systems emphasizing additive, subtractive and/or hybrid manufacturing processes in a collaborative, predictive, decisive, and intelligent environment. Relevant electronic databases were searched, and 248 articles were selected for qualitative synthesis. Our review suggests that significant improvements are required in connectivity, data sensing, and collection to enhance both subtractive and additive technologies, though the pervasive use of AI by machines and software helps to automate processes. An intelligent system is highly recommended in both conventional and non-conventional subtractive manufacturing (SM) methods to monitor and inspect the workpiece conditions for defect detection and to control the machining strategies in response to instantaneous output. Similarly, AM product quality can be improved through the online monitoring of melt pool and defect formation using suitable sensing devices followed by process control using machine learning (ML) algorithms. Challenges in implementing intelligent additive and subtractive manufacturing systems are also discussed in the article. The challenges comprise difficulty in self-optimizing CNC systems considering real-time material property and tool condition, defect detections by in-situ AM process monitoring, issues of overfitting and underfitting data in ML models and expensive and complicated set-ups in hybrid manufacturing processes.

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“…First, relatively high energy is required for melting. Secondly, the low ductility of these materials can lead to the appearance of cracks caused by thermal stresses at high cooling rates [ 95 ]. Moreover, it leads to a low processability of the alloys at the ambient temperatures.…”

Section: Classification Of the Mam Processes Used For Ti 2 ...mentioning

confidence: 99%

A Review—Additive Manufacturing of Intermetallic Alloys Based on Orthorhombic Titanium Aluminide Ti2AlNb

et al. 2023

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Titanium alloys based on orthorhombic titanium aluminide Ti2AlNb are promising refractory materials for aircraft engine parts in the operating temperature range from 600–700 °C. Parts made of Ti2AlNb-based alloys by traditional technologies, such as casting and metal forming, have not yet found wide application due to the sensitivity of processability and mechanical properties in chemical composition and microstructure compared with commercial solid-solution-based titanium alloys. In the last three decades, metal additive manufacturing (MAM) has attracted the attention of scientists and engineers for the production of intermetallic alloys based on Ti2AlNb. This review summarizes the recent achievements in the production of O-phase-based Ti alloys using MAM, including the analysis of the feedstock materials, technological processes, machines, microstructure, phase composition and mechanical properties. Powder bed fusion (PBF) and direct energy deposition (DED) are the most widely employed MAM processes to produce O-phase alloys. MAM provides fully dense, fine-grained material with a superior combination of mechanical properties at room temperature. Further research on MAM for the production of critical parts made of Ti2AlNb-based alloys can be focused on a detailed study of the influence of post-processing and chemical composition on the formation of the structure and mechanical properties, including cyclic loading, fracture toughness, and creep resistance.

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Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: a review

Cited by 32 publications

References 144 publications

Failure-based design validation for effective repair of multi-metal additive manufacturing: the case of remanufacturable brake caliper

Failure-based design validation for effective repair of multi-metal additive manufacturing: the case of remanufacturable brake caliper

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

A Review—Additive Manufacturing of Intermetallic Alloys Based on Orthorhombic Titanium Aluminide Ti2AlNb

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