Surface Finish Improvement of Additive Manufactured Metal Parts

Hassanin, Hany; ElShaer, Amr; Benhadj-Djilali, R.; Modica, Francesco; Fassi, Irene

doi:10.1007/978-3-319-68801-5_7

Cited by 48 publications

(20 citation statements)

References 60 publications

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“…Additive manufacturing (AM) offers additional flexibility in the design and manufacturing of parts, particularly the ability to fabricate complex geometries without the need for custom tools [2]. Selective laser melting (SLM) offers superior dimensional accuracy and material quality of the fabricated parts [3].…”

Section: Introductionmentioning

confidence: 99%

Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

et al. 2018

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Additive manufacturing (AM) of high-strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to the satisfaction of the parts’ quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) was used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map was developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. This study is also aimed at reducing the amount of post-processing needed according to the optimal processing window detected.

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Section: Introductionmentioning

confidence: 99%

Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

et al. 2018

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“…Additive manufacturing (AM) offers additional flexibility in the design and manufacturing of parts, particularly the ability to fabricate complex geometries without the need for custom tools [2]. SLM offers superior dimensional accuracy and material quality of the fabricated parts [3].…”

Section: Introductionmentioning

confidence: 99%

“…Read et al [12] used the response surface methodology (RSM) to evaluate the influence of SLM process parameters on part porosity. Their study was limited by the use of a laser power up to 200 W. The results showed that minimum porosity was obtained at a critical energy density of 60 J/mm 3 . Abouelkhair et al [13] used one factor at a time (OFAT) method to optimize the SLM process parameters for producing dense parts.…”

Section: Introductionmentioning

confidence: 99%

Effect of SLM Process Parameters on the Quality of Al Alloy Parts; Part I: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Maamoun¹,

Xue²,

Elbestawi³

et al. 2018

Preprint

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Additive manufacturing (AM) of high strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to satisfy the part quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) is used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for the AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map is developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. The second part of this study investigates the effect of SLM process parameters on the microstructure and mechanical properties of the same Al alloys. This comprehensive study is also aimed at reducing the amount of post-processing needed.

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“…Ablation method is the other process using a laser that can evaporate the materials and the defected layer can be removed by this way from the 3D manufactured part. Overall, the laser processing of AM parts can improve considerably the roughness, wear resistance, microstructure, and porosity based on various research reports [137][138][139]. Cernasejus et al applied the laser processing using Nd: YAG laser for additively fabricated stainless-steel parts.…”

Section: Laser Processingmentioning

confidence: 99%

Metal additive manufacturing in the commercial aviation industry: A review

Gisario

Kazarian

Martina

et al. 2019

Journal of Manufacturing Systems

406

124

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The applications of Additive Manufacturing (AM) have been grown up rapidly in various industries in the past few decades. Among them, aerospace has been attracted more attention due to heavy investment of the principal aviation companies for developing the AM industrial applications. However, many studies have been going on to make it more versatile and safer technology and require making development in novel materials, technologies, process design, and cost efficiency. As a matter of fact, AM has a great potential to make a revolution in the global parts manufacturing and distribution while offering less complexity, lower cost, and energy consumption, and very highly customization. The current paper aims to review the last updates on AM technologies, material issues, postprocesses, and design aspects, particularly in the aviation industry. Moreover, the AM process is investigated economically including various cost models, spare part digitalization and environmental consequences. This review would be helpfully applied in both academia and industry as well.

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Surface Finish Improvement of Additive Manufactured Metal Parts

Cited by 48 publications

References 60 publications

Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Effect of SLM Process Parameters on the Quality of Al Alloy Parts; Part I: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Metal additive manufacturing in the commercial aviation industry: A review

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