Unit process energy consumption analysis and models for Electron Beam Melting (EBM): Effects of process and part designs

Lunetto, Vincenzo; Galati, Manuela; Settineri, Luca; Iuliano, Luca

doi:10.1016/j.addma.2020.101115

Cited by 26 publications

(23 citation statements)

References 16 publications

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“…The amount of deposited material (m EBM , which accounts for the weight of the components, the support structures, and the allowances removed when finishing) was 1445.5 g; therefore, the specific electric energy consumption of the EBM machine, including the productive and nonproductive times, was 184.3 MJ/kg. This value is coherent with the experimental characterization performed on the same AM machine by Lunetto et al [37], and it is only slightly higher than the 61-177 MJ/kg range proposed by Kellens et al [26] in their literature review. The average deposition rate, which was computed as the ratio of m EBM to the build time, was 8.5 • 10 −2 kg/h.…”

Section: Electron Beam Meltingsupporting

confidence: 91%

The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components

Atzeni

Catalano

Priarone

et al. 2021

Int J Adv Manuf Technol

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Additive manufacturing (AM) processes allow complex geometries to be produced with enhanced functionality, but technological challenges still have to be dealt with, in terms of surface finish and achieved tolerances. Among the consolidated powder-bed fusion processes, electron beam melting (EBM), which allows almost stress-free parts to be manufactured with a high productivity and minimum use of support structures, suffers from a poor surface quality. Thus, finishing processes have to be performed. The same geometrical complexity, which is considered one of the benefits of AM, becomes an issue when finishing is applied, in particular when internal features are present. Unconventional isotropic superfinishing processes could be a solution to this problem since they can generate a low surface roughness on complex geometries. However, the performance characteristics, with regard to the environmental sustainability and economic aspects, need to be evaluated since they are key factors that must be considered for decision-support tools when selecting a finishing process. The technological feasibility of the isotropic superfinishing (ISF) process, applied to Ti-6Al-4V parts produced by electron beam melting, is investigated in this paper by considering the dimensional and geometrical deviations induced by the finishing treatment, and from observations of the surface morphology. A significant reduction in surface roughness, Sa, to around 4 μm, has been observed on the most irregular surfaces, although the original shape is maintained. Environmental sustainability has been analyzed for all the manufacturing steps, from powder production to part fabrication, to the finishing process, and both the cumulative energy demand and material waste have been accounted for. The economic impact of the whole manufacturing chain has been evaluated, and the advantages of the ISF process are pointed out.

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Section: Electron Beam Meltingsupporting

confidence: 91%

The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components

Atzeni

Catalano

Priarone

et al. 2021

Int J Adv Manuf Technol

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“…The outer boundary of the part is first built, known as contouring, and then the powder inside the contour begins to melt, forming a single sheet. [71,72].…”

Section: Electron Beam Meltingmentioning

confidence: 99%

A review of additive manufacturing of Mg-based alloys and composite implants

Zamani

Ghazanfari

Erabi

et al. 2021

jcc

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Magnesium based materials are considered promising biodegradable metals for orthopedic bone implant applications as they exhibit similar density and elastic modulus to that of bone, biodegradability, and excellent osteogenic properties. The use of Mg based biomaterials eliminates the limitations of currently used implant materials such as stress shielding and the need for the second surgery. Recently, the development of Mg-based implants has attracted significant attention. Additive manufacturing is one of the effective techniques to develop Mg based implants. Additive manufacturing which could be named 3D printing is a transformative and rapid method of producing industrial parts with in the acceptable dimensional range. Therefore, recent investigations have tried to apply this method for the development of Mg-based implants. This state-of-the-art review focuses on the additive manufacturing of Mg biodegradable materials and their in-vitro corrosion and degradation, and mechanical properties. The future directions to develop Mg biodegradable materials are reported through summarization of current achievements.

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“…Comprehensive material research in close cooperation with machine technology development enabled, that SLA and FFF can be used recently for the realization of functional composites e.g., with piezoelectric, conductive, ferroelectric, or magnetic properties [8][9][10][11][12]. Whilst metal parts are mainly printed directly by the different variants of Selective Laser Sintering (SLS), Selective Laser Melting (SLM), or quite recently by Electron Beam Melting (EBM) [13][14][15][16], ceramic parts can be printed via SLA and FFF using highly filled low viscous resins (SLA) or molten thermoplastics (FFF). In the case of SLA, this technology has been commercialized (Lithoz GmbH, Vienna, Austria, www.lithoz.com), recent research can be found in [17][18][19][20][21][22].…”

Section: Introductionmentioning

confidence: 99%

New Feedstock System for Fused Filament Fabrication of Sintered Alumina Parts

Nötzel

Hanemann

2020

Materials

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Only a few 3D-printing techniques are able to process ceramic materials and exploit successfully the capabilities of additive manufacturing of sintered ceramic parts. In this work, a new two component binder system, consisting of polyethyleneglycol and polyvinylbutyral, as well stearic acid as surfactant, was filled with submicron sized alumina up to 55 vol.% and used in fused filament fabrication (FFF) for the first time. The whole process chain, as established in powder injection molding of ceramic parts, starting with material selection, compounding, measurement of shear rate and temperature dependent flow behavior, filament fabrication, as well as FFF printing. A combination of solvent pre-debinding with thermal debinding and sintering at a reduced maximum temperature due to the submicron sized alumina and the related enhanced sinter activity, enabled the realization of alumina parts with complex shape and sinter densities around 98 % Th. Finally the overall shrinkage of the printed parts were compared with similar ones obtained by micro ceramic injection molding.

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Unit process energy consumption analysis and models for Electron Beam Melting (EBM): Effects of process and part designs

Cited by 26 publications

References 16 publications

The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components

The technology, economy, and environmental sustainability of isotropic superfinishing applied to electron-beam melted Ti-6Al-4V components

A review of additive manufacturing of Mg-based alloys and composite implants

New Feedstock System for Fused Filament Fabrication of Sintered Alumina Parts

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