Scientific, technological and economic issues in metal printing and their solutions

DebRoy, T.; Mukherjee, T.; Milewski, J.; Elmer, J. W.; Ribic, B.; Blecher, J. J.; Zhang, Wei

doi:10.1038/s41563-019-0408-2

Cited by 352 publications

(93 citation statements)

References 33 publications

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“…This leads to columnar grains along the build direction in most additively manufactured metallic materials, which cause property anisotropy, reduce mechanical performance and increase tendency toward hot tearing. Therefore, a key objective for metal AM is to replace coarse columnar grains with fine, equiaxed grains throughout the part [1][2][3][4] .…”

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confidence: 99%

Grain structure control during metal 3D printing by high-intensity ultrasound

et al. 2020

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Additive manufacturing (AM) of metals, also known as metal 3D printing, typically leads to the formation of columnar grain structures along the build direction in most as-built metals and alloys. These long columnar grains can cause property anisotropy, which is usually detrimental to component qualification or targeted applications. Here, without changing alloy chemistry, we demonstrate an AM solidification-control solution to printing metallic alloys with an equiaxed grain structure and improved mechanical properties. Using the titanium alloy Ti-6Al-4V as a model alloy, we employ high-intensity ultrasound to achieve full transition from columnar grains to fine (~100 µm) equiaxed grains in AM Ti-6Al-4V samples by laser powder deposition. This results in a 12% improvement in both the yield stress and tensile strength compared with the conventional AM columnar Ti-6Al-4V. We further demonstrate the generality of our technique by achieving similar grain structure control results in the nickel-based superalloy Inconel 625, and expect that this method may be applicable to other metallic materials that exhibit columnar grain structures during AM.

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confidence: 99%

Grain structure control during metal 3D printing by high-intensity ultrasound

et al. 2020

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“…Electrodes in eDEP are generally made of electrically conductive materials, such as silver, brass, and gold. A range of methods, from conventional photolithography [ 62 , 63 ] to the latest 3D metal printing [ 64 , 65 ] technologies, for the fabrication of electrodes. The major drawbacks of using eDEP are Joule heating [ 27 , 31 , 32 , 33 ], fouling effects [ 33 ], and electrochemical reactions that generate toxic species mainly due to electrode disintegration [ 33 , 66 ].…”

Section: Discussionmentioning

confidence: 99%

Insulator Based Dielectrophoresis: Micro, Nano, and Molecular Scale Biological Applications

Benhal

Quashie

Kim

et al. 2020

Sensors

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Insulator based dielectrophoresis (iDEP) is becoming increasingly important in emerging biomolecular applications, including particle purification, fractionation, and separation. Compared to conventional electrode-based dielectrophoresis (eDEP) techniques, iDEP has been demonstrated to have a higher degree of selectivity of biological samples while also being less biologically intrusive. Over the past two decades, substantial technological advances have been made, enabling iDEP to be applied from micro, to nano and molecular scales. Soft particles, including cell organelles, viruses, proteins, and nucleic acids, have been manipulated using iDEP, enabling the exploration of subnanometer biological interactions. Recent investigations using this technique have demonstrated a wide range of applications, including biomarker screening, protein folding analysis, and molecular sensing. Here, we review current state-of-art research on iDEP systems and highlight potential future work.

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“…However, metal AM for most industrial sectors is still at a stage of research and development, with limited industrial applications when compared to the full potential of metal AM. The high cost of machines and consumables, long printing time, and inferior quality of printed parts are some of the factors that hinder the widespread application of metal 3D printing [ 16 ]. Nevertheless, continuous development of metal AM makes it popular in aerospace, biomedicine, and automotive industries [ 17 ].…”

Section: Role Of Additive Manufacturing In Icmentioning

confidence: 99%

Application of Stereolithography Based 3D Printing Technology in Investment Casting

2020

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Advanced methods for manufacturing high quality parts should be used to ensure the production of competitive products for the world market. Investment casting (IC) is a process where a wax pattern is used as a sacrificial pattern to manufacture high precision casting of solid metal parts. Rapid casting is in turn, a technique that eases the IC process by combining additive manufacturing (AM) technologies with IC. The use of AM technologies to create patterns for new industrial products is a unique opportunity to develop cost-effective methods for producing investment casting parts in a timely manner. Particularly, stereolithography (SLA) based AM is of interest due to its high dimensional accuracy and the smooth surface quality of the printed parts. From the first appearance of commercially available SLA printers in the market, it took a few decades until desktop SLA printers became available to consumers at a reasonable price. Therefore, the aim of this review paper is to analyze the state-of-the-art and applicability of SLA based 3D printing technology in IC manufacturing, as SLA based AM technologies have been gaining enormous popularity in recent times. Other AM techniques in IC are also reviewed for comparison. Moreover, the SLA process parameters, material properties, and current issues are discussed.

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Scientific, technological and economic issues in metal printing and their solutions

Cited by 352 publications

References 33 publications

Grain structure control during metal 3D printing by high-intensity ultrasound

Grain structure control during metal 3D printing by high-intensity ultrasound

Insulator Based Dielectrophoresis: Micro, Nano, and Molecular Scale Biological Applications

Application of Stereolithography Based 3D Printing Technology in Investment Casting

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