Download or read book Investigation of Electrochemical Post processing Procedure for Ti 6Al 4V Lattice Structure Manufactured by Direct Metal Laser Sintering DMLS written by Julien Marleau-Finley and published by . This book was released on 2018 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: "Additive manufacturing has become very popular nowadays to create complex geometries that can not be achieved by any other manufacturing process. This technology has its benefits as well as drawbacks. One of the main drawback is that parts manufactured from this technology typically have relatively high surface roughness which leads to low tribological properties, low aerodynamic properties, a lower resistance to fatigue, and low aesthetics. This in turn has a direct impact on the mechanical properties and the useful life of the manufactured part. The purpose of this study is to investigate and characterise the electrochemical polishing and chemical etching methods as a post-process treatment to improve the surface finish of lattice structures made from Ti-6Al-4V manufactured by Direct Metal Laser Sintering (DMLS). This material is of interest because it is frequently used in aerospace and biomedical field due to its mechanical strength, light weight, and biocompatibility. Both aerospace and bio-implant industries have high interest in additive manufacturing technology but are concerned about the achievable surface finish of DMLS process. This work will provide critical information on the surface and geometrical characterisation as well as the post-process treatment of a Ti-6Al-4V lattice. The metrological data will be analysed to determine how the post-process treatment affects the surface finish, considering the final roughness (Average roughness, Ra) and geometrical integrity of lattice samples. " --

Download or read book Post Processing Techniques for Metal Based Additive Manufacturing written by Hao Wang and published by CRC Press. This book was released on 2023-09-04 with total page 289 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book shares insights on post-processing techniques adopted to achieve precision-grade surfaces of additive manufactured metals including material characterization techniques and the identified material properties. Post-processes are discussed from support structure removal and heat treatment to the material removal processes including hybrid manufacturing. Also discussed are case studies on unique applications of additive manufactured metals as an exemplary of the considerations taken during post-processing design and selection. Addresses the critical aspect of post-processing for metal additive manufacturing Provides systematic introduction of pertinent materials Demonstrates post-process technique selection with the enhanced understanding of material characterization methods and evaluation Includes in-depth validation of ultra-precision machining technology Reviews precision fabrication of industrial-grade titanium alloys, steels, and aluminium alloys, with additive manufacturing technology The book is aimed at researchers, professionals, and graduate students in advanced manufacturing, additive manufacturing, machining, and materials processing.

Download or read book Proceedings of the 3rd International Conference on Advanced Surface Enhancement INCASE 2023 written by Niroj Maharjan and published by Springer Nature. This book was released on with total page 418 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Proceedings of CASICAM 2022 written by Khalid Zarbane and published by Springer Nature. This book was released on 2023-07-29 with total page 300 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book contains selected papers from the conference CASICAM'22, presenting the latest advancements and discoveries in Additive Manufacturing (AM) technology. The chapters cover a wide range of topics related to AM, including design for additive manufacturing, functionally graded additive manufacturing (FGAM), new and innovative materials for AM, AM parts/processes modeling and simulation, AM process optimization, monitoring, and qualification, 4D printing, AM post-processing operations, AM product metrology and quality control, AM standards and certification, health, safety, and environment challenges, education, training, and research strategy, and AM applications and challenges.

Download or read book Additive Manufacturing of High Performance Metallic Materials written by Robert Pederson and published by Elsevier. This book was released on 2023-09-19 with total page 580 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive Manufacturing of High-Performance Metallic Materials outlines the state-of-the-art on AM in high performance materials utilizing the two most industrially interesting routes of powder bed fusion (PBF) and directed energy deposition (DED). The book delves into Feedstock, Processing, Monitoring and control, Modeling and simulation, and Surface and thermal post-treatments. It specifically addresses materials and the most relevant and high performance applications, namely Ni-based alloys and Titanium alloys, and also provides insights into potential applications through illustrative case studies. With each chapter contributed by experts in the field, this work will serve as a comprehensive resource for graduate students and practitioners alike. - Covers the entire value chain relevant to additive manufacturing spanning feedstock, processing, monitoring, post-treatment, testing and applications - Includes the fundamental understanding of varied associated aspects derived from both extensive experimental knowledge and theoretical investigations - Addresses key materials relevant to varied high performance applications, namely Superalloys and Ni-based alloys

Download or read book Precision Metal Additive Manufacturing written by Richard Leach and published by CRC Press. This book was released on 2020-09-21 with total page 357 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing (AM) is a fast-growing sector with the ability to evoke a revolution in manufacturing due to its almost unlimited design freedom and its capability to produce personalised parts locally and with efficient material use. AM companies, however, still face technological challenges such as limited precision due to shrinkage, built-in stresses and limited process stability and robustness. Moreover, often post-processing is needed due to high roughness and remaining porosity. Qualified, trained personnel are also in short supply. In recent years, there have been dramatic improvements in AM design methods, process control, post-processing, material properties and material range. However, if AM is going to gain a significant market share, it must be developed into a true precision manufacturing method. The production of precision parts relies on three principles: Production is robust (i.e. all sensitive parameters can be controlled). Production is predictable (for example, the shrinkage that occurs is acceptable because it can be predicted and compensated in the design). Parts are measurable (as without metrology, accuracy, repeatability and quality assurance cannot be known). AM of metals is inherently a high-energy process with many sensitive and inter-related process parameters, making it susceptible to thermal distortions, defects and process drift. The complete modelling of these processes is beyond current computational power, and novel methods are needed to practicably predict performance and inform design. In addition, metal AM produces highly textured surfaces and complex surface features that stretch the limits of contemporary metrology. With so many factors to consider, there is a significant shortage of background material on how to inject precision into AM processes. Shortage in such material is an important barrier for a wider uptake of advanced manufacturing technologies, and a comprehensive book is thus needed. This book aims to inform the reader how to improve the precision of metal AM processes by tackling the three principles of robustness, predictability and metrology, and by developing computer-aided engineering methods that empower rather than limit AM design. Richard Leach is a professor in metrology at the University of Nottingham and heads up the Manufacturing Metrology Team. Prior to this position, he was at the National Physical Laboratory from 1990 to 2014. His primary love is instrument building, from concept to final installation, and his current interests are the dimensional measurement of precision and additive manufactured structures. His research themes include the measurement of surface topography, the development of methods for measuring 3D structures, the development of methods for controlling large surfaces to high resolution in industrial applications and the traceability of X-ray computed tomography. He is a leader of several professional societies and a visiting professor at Loughborough University and the Harbin Institute of Technology. Simone Carmignato is a professor in manufacturing engineering at the University of Padua. His main research activities are in the areas of precision manufacturing, dimensional metrology and industrial computed tomography. He is the author of books and hundreds of scientific papers, and he is an active member of leading technical and scientific societies. He has been chairman, organiser and keynote speaker for several international conferences, and received national and international awards, including the Taylor Medal from CIRP, the International Academy for Production Engineering.

Download or read book Residual Stress of Ti6A14V ELI Parts Manufactured by Direct Metal Laser Sintering written by Ian Van Zyl and published by . This book was released on 2016 with total page 288 pages. Available in PDF, EPUB and Kindle. Book excerpt: This study focuses on the residual stress in Ti6Al4V (ELI) parts manufactured by direct metal laser sintering (DMLS). During DMLS a laser beam scans over the powder layer thus melting the powder and previous layer. High-concentrated energy input leads to high thermal gradients. The track-by-track, layer-by-layer nature of DMLS technology and the thermocycling of the process leads to complex stress distribution and deformation of parts during manufacturing. A literature review of the DMLS process is given; the capabilities of DMLS are overviewed, and a practical medical solution is demonstrated as a prominent market component of DMLS and its capabilities. Types of residual stress, its origin and effect on the performance of materials are described. Focus is given to the methods for quantitative and qualitative determination of residual stress in DMLS objects. The thermal gradient and shrinkage play a vital role in the development of residual stresses. Methodology for the investigations of the microstructure, roughness, deformation and microhardness of the specimens are outlined. Experiments which were conducted with their respective results are included, the results being scrutinized as well as the relevant interpretation to reach adequate scientific conclusions. Relative comparisons are also done in terms of received data and literature. Some numerical simulations are done for predictive and comparative purposes. The results show high values of residual stress in Ti6Al4V (ELI) specimens produced by DMLS. The residual stresses in samples with successively increasing thickness and in primitive 3D components were investigated. It was found that volumetric and shape relations in terms of residual stress and DMLS objects exist. Applied post process heat treatment is adequate in relieving the majority of residual stress. The sensitivity of Ti6Al4V (ELI) alloy to interstitial elements is also indicated in the data during heat treatment. The consequences of residual stress experienced during this study demand creative solutions for the purpose of a wider application of this technology. Some promising directions for further investigation of residual stress in DMLS objects based on the study’s findings are done.

Download or read book DIRECT METAL LASER SINTERING OF TI 6AL 4V ALLOY PROCESS PROPERTY GEOMETRY EMPIRICAL MODELING AND OPTIMIZATION written by Behzad Fotovvati and published by . This book was released on 2020 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Direct metal laser sintering (DMLS) is a widely used powder bed fusion (PBF) additive manufacturing (AM) technology that offers extensive capabilities to fabricate complex metallic components. In the DMLS process, part fabrication involves small moving melt-pools formed by the interaction of laser beam and metal powders. The formation of a melt-pool and subsequently its rapid solidification results in alteration of properties and microstructure of the product. Therefore, understanding and predicting relationships between DMLS process parameters and melt-pool characteristics is critical to control and improve the properties of parts. The melt-pool formation in this process is very similar to what occurs in metal laser welding, having solid metallic parts rather than metal powders, plus laser welding is more investigated and is better known compare to DMLS. So, a critical review of the literature on experimental and modeling studies on laser welding, with the focus being on the influence of process parameters on geometry, thermodynamics, fluid dynamics, microstructure, and porosity characteristics of the melt-pool is presented. However, the DMLS process has several variables, altering which increases the complexity of the correlations between them and the final properties. A solution is to isolate the variable sets from the other ones during the investigation. Therefore, keeping all the processing parameters constant, an investigation of the size and geometry dependence of the dimensional accuracy of the DMLS process is presented. For all features, with different geometries and different sizes, the percent error significantly increases with decreasing the feature size. Then, the effect of thickness, orientation, distance from free edges, and height on the mechanical properties and their correlations to material microstructure and thermal history as dictated by DMLS process parameters are investigated and the results are correlated to the porosity volume fraction and their elongation direction, prior grain width and orientation, nanoparticle volume fraction, martensitic decomposition to + and orthorhombic structure, and Oxygen content variation. Furthermore, the influence of five most influential DMLS processing parameters, i.e. laser power, scan speed, hatch spacing, layer thickness, and stripe width, on relative density, microhardness, and surface roughness are thoroughly investigated. Two design of experiment (DoE) methods, including the Taguchi and fractional factorial DoE for response surface method (RSM), along with an artificial neural network (ANN) are designed and trained to predict the response values. A multi-objective RSM model is developed for the optimization of DMLS processing parameters. It is shown that the proposed ANN model can most accurately predict various response properties of DMLS components..

Download or read book Laser Additive Manufacturing of High Performance Materials written by Dongdong Gu and published by Springer. This book was released on 2015-04-21 with total page 322 pages. Available in PDF, EPUB and Kindle. Book excerpt: This book entitled “Laser Additive Manufacturing of High-Performance Materials” covers the specific aspects of laser additive manufacturing of high-performance new materials components based on an unconventional materials incremental manufacturing philosophy, in terms of materials design and preparation, process control and optimization and theories of physical and chemical metallurgy. This book describes the capabilities and characteristics of the development of new metallic materials components by laser additive manufacturing process, including nanostructured materials, in situ composite materials, particle reinforced metal matrix composites, etc. The topics presented in this book, similar as laser additive manufacturing technology itself, show a significant interdisciplinary feature, integrating laser technology, materials science, metallurgical engineering and mechanical engineering. This is a book for researchers, students, practicing engineers and manufacturing industry professionals interested in laser additive manufacturing and laser materials processing. Dongdong Gu is a Professor at College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics (NUAA), PR China.

Download or read book Additive Manufacturing of Metals written by John O. Milewski and published by Springer. This book was released on 2017-06-28 with total page 351 pages. Available in PDF, EPUB and Kindle. Book excerpt: This engaging volume presents the exciting new technology of additive manufacturing (AM) of metal objects for a broad audience of academic and industry researchers, manufacturing professionals, undergraduate and graduate students, hobbyists, and artists. Innovative applications ranging from rocket nozzles to custom jewelry to medical implants illustrate a new world of freedom in design and fabrication, creating objects otherwise not possible by conventional means. The author describes the various methods and advanced metals used to create high value components, enabling readers to choose which process is best for them. Of particular interest is how harnessing the power of lasers, electron beams, and electric arcs, as directed by advanced computer models, robots, and 3D printing systems, can create otherwise unattainable objects. A timeline depicting the evolution of metalworking, accelerated by the computer and information age, ties AM metal technology to the rapid evolution of global technology trends. Charts, diagrams, and illustrations complement the text to describe the diverse set of technologies brought together in the AM processing of metal. Extensive listing of terms, definitions, and acronyms provides the reader with a quick reference guide to the language of AM metal processing. The book directs the reader to a wealth of internet sites providing further reading and resources, such as vendors and service providers, to jump start those interested in taking the first steps to establishing AM metal capability on whatever scale. The appendix provides hands-on example exercises for those ready to engage in experiential self-directed learning.

Download or read book Titanium written by Matthew J. Donachie and published by ASM International. This book was released on 2000 with total page 381 pages. Available in PDF, EPUB and Kindle. Book excerpt: Designed to support the need of engineering, management, and other professionals for information on titanium by providing an overview of the major topics, this book provides a concise summary of the most useful information required to understand titanium and its alloys. The author provides a review of the significant features of the metallurgy and application of titanium and its alloys. All technical aspects of the use of titanium are covered, with sufficient metals property data for most users. Because of its unique density, corrosion resistance, and relative strength advantages over competing materials such as aluminum, steels, and superalloys, titanium has found a niche in many industries. Much of this use has occurred through military research, and subsequent applications in aircraft, of gas turbine engines, although more recent use features replacement joints, golf clubs, and bicycles.Contents include: A primer on titanium and its alloys, Introduction to selection of titanium alloys, Understanding titanium's metallurgy and mill products, Forging and forming, Castings, Powder metallurgy, Heat treating, Joining technology and practice, Machining, Cleaning and finishing, Structure/processing/property relationships, Corrosion resistance, Advanced alloys and future directions, Appendices: Summary table of titanium alloys, Titanium alloy datasheets, Cross-reference to titanium alloys, Listing of selected specification and standardization organizations, Selected manufacturers, suppliers, services, Corrosion data, Machining data.

Download or read book Experimental Investigation of Ti 6Al 4V Microstructure and Mechanical Properties After Laser Powder Bed Fusion LPBF Manufacturing and Post processing written by Naeem N. Mohamed Eshawish and published by . This book was released on 2023 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: This note is part of Quality testing.

Download or read book Laser Wire Deposition Additive Manufacturing of Ti 6Al 4V for the Aerospace Industry written by Nejib Chekir and published by . This book was released on 2019 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt: "Additive manufacturing (AM) is an attractive solution to reduce processing cost of complex components. The interest of the aerospace industry into Ti-6Al-4V resides in its excellent strength to weight ratio and corrosion resistance properties. As of today, control of the process to structure to property relationship for AM technologies remains challenging. This research investigates the effects of some key laser wire deposition (LWD) parameters and various post deposition heat treatments on the developed microstructure and subsequent properties of the deposited Ti-6Al-4V materials. The effect of two different travel speeds on the structural development of thin Ti-6Al-4V deposits was investigated. A travel speed set at 1.4 mm/s promoted recrystallization of columnar prior [beta] grains into horizontal prior [beta] grains and a diffusion-controlled type of microstructure. A travel speed set at 7.2 mm/s resulted in higher cooling rates that produced a refined microstructure while no recrystallization of the prior [beta] grains has been observed. Next the effect of five different post deposition heat treatments were investigated. A stress relief preserved the morphology of the deposited samples while annealing or HIP, followed or not by aging, coarsened the developed microstructure. The lower travel speed exhibited a strong anisotropy in elongation with lower values generated along the build direction as opposed to the isotropic results in elongation at higher travel speed. Moreover, samples processed at 7.2 mm/s produced high strength meeting the minimum wrought requirements as set by the AMS4911. Eventually, the grain boundary strengthening mechanism with regards to the [alpha] platelets thicknesses was found to be travel speed dependent. Thick samples were characterized by the deposition of multiple lateral beads within one layer. Thermal history was first investigated through the development of a FEM model reproducing the deposition process. Typical macrostructures and microstructures that developed post deposit were then investigated. Subsequent static tensile properties were found to be hardly meeting the cast minimum requirements as set by the ASTM F1108. No anisotropy in the impact toughness properties was observed. Eventually, HIP did not induce any major improvement of the mechanical properties for both thin and thick specimens and is not required for LWD applications. All the previous findings were eventually applied for the printing of a large Ti-6Al-4V aerospace component. The deposition strategy was presented. Destructive and non-destructive testing were done to check the printed part geometry and the process to structure to properties relationship. The printed part was characterized with a buy-to-fly ratio (BTF) of about 3.2:1 as opposed to a BTF ratio of 30.8:1 when using conventional subtractive processes." --

Download or read book Development of a Non destructive Testing Method to Determine the Tensile Fatigue Life of Ti 6Al 4V Additively Manufactured Parts written by and published by . This book was released on 2020 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: Additive manufacturing -- AM -- DIC -- Digital image correlation -- Direct metal laser sintering -- DMLS -- Fatigue life prediction -- Fatigue testing -- Ti-6Al-4V

Download or read book Fabrication of Ti 6Al 4V Structures Using Direct Metal Deposition DMD Process written by Arun Thomas and published by . This book was released on 2004 with total page 232 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Cellular Design for Laser Freeform Fabrication written by Olaf Rehme and published by Cuvillier Verlag. This book was released on 2010-03-18 with total page 304 pages. Available in PDF, EPUB and Kindle. Book excerpt: Cellular materials are spread all across the world. They can be found in nature, e.g. in bone and wood, as well as in engineering applications such as honeycomb sheets and aluminum foams to name but a few. Cellular materials have some unique properties which allow new and innovative applications beyond the scope of solid engineering materials. Especially their low density and therefore their outstanding stiffness-to-weight-ratio is of greatest importance in most applications. Functions of cellular materials could be lightweight structures of high stiffness, damping and absorption of mechanical energy, vibration control, acoustic absorption, heat exchange, filtering and numerous other tasks. Generally, a combination of these tasks in one part exhibits an optimized and therefore innovative overall performance. One recent development in production technologies is the field of Laser Freeform Fabrication (LFF) processes where parts are manufactured by application of thin layers of powder or sometimes liquid material. A laser beam melts and solidifies the material along contour lines and hatch areas according to slices of a corresponding 3D-CAD model. Among these processes the Selective Laser Melting (SLM) technology was advanced based upon the work in this thesis to allow the manufacture of periodic, open-cell lattice structures from engineering materials such as stainless steel, titanium, etc. In contrast to other cellular materials these lattice structures can be of well-defined, nearly arbitrary shape. Due to the layerwise fabrication the SLM process is also capable of creating lattice cores surrounded by solid shells allowing new degrees of geometric freedom in engineering design that was never experienced before in conventional machining. This allows the development of interesting new applications such as medical implants where the main issues are the improvement of osseointegration and realization of physioelastic material properties for an optimized bond between the implant and surrounding tissue. Lattice structures obtained from the SLM process can meet these requirements. This thesis contributes to the understanding of the mechanical properties of the new material class of SLM lattice structures. Their future incorporation in engineering designs requires a profound knowledge of failure mechanisms and operational limits. Therefore, a comprehensive summary is given on the state-of-the-art of cellular materials followed by a dedicated analysis on Laser Freeform Fabrication and an in-depth validation of the Selective Laser Melting capabilities. Readers with advanced knowledge on cellular materials or Laser Freeform Fabrication may skip sections 2 or 3, respectively. Next, all process constraints and boundary conditions for the manufacture of SLM lattice structures are elaborated. Then a bilateral approach was chosen to derive scaling laws and optimize the SLM lattice structures for given tasks. Firstly, a theoretical analysis comprises the examination of structural hypotheses for isotropic cellular materials before a generalized theory is developed for anisotropic SLM lattice structures. Different cubic, polyhedral and rhombic cell types are evaluated towards their producibility. Some of these cell types are preselected and are subject to numerical analysis where their mechanical properties are derived on the basis of the space framework theory. Secondly, an extensive experimental evaluation of test specimens is given. This includes examinations of the properties of SLM solids, the producibility of SLM lattice structures in terms of dimensions and testing of their mechanical properties such as strength and elasticity in compression, tension and shear load. The test procedures are divided in three stages. The first stage comprises the examination of the specific strength in dependence of the cell type to narrow down few optimum cell types for different applications. In the second and third stage these cell types are investigated towards their elasticity and strength in dependence of the cell size. Finally, this thesis concludes with scaling laws provided in accordance with the theoretical and experimental results. Opposed to simple power laws used for cellular materials these newly developed scaling laws consider leaps in properties at higher, so-called critical relative densities which can be obtained from SLM due to its high degree of design freedom. At the critical relative density SLM lattice structures cease being frameworks and become rather solids with pores. For future applications these scaling laws can be applied by design engineers to match particular requirements that can only be fulfilled by Laser Freeform Fabrication and its degrees of freedom in design. For the sake of completeness some sample applications in the field of medical implants are given in this thesis, which involve these scaling laws.

Download or read book The Effect of Process Parameters on Laser Deposited Ti 6Al 4V written by Troy Austin Davis and published by . This book was released on 2004 with total page 168 pages. Available in PDF, EPUB and Kindle. Book excerpt: The purpose of this research is to understand how the process parameters surrounding the Direct Metal Deposition (DMD) process affect the properties of the deposition. The powder used in this research is pre-alloyed titanium powder (Ti-6Al-4V), containing 6% wt. aluminum and 4% wt. vanadium. A few process parameters involved with the DMD include the laser power, traverse speed, powder flow rate, and gas flow rates. Due to the detrimental effect of oxygen on titanium, oxygen content is one of the main deposition properties of significance involved with this research. In addition to the oxygen content, the powder efficiency, build rate, and build height per layer are also properties of importance. The experiments varied process parameters such as the laser power, CNC velocity, gas flow rate, powder flow rate, and final deposition geometry. In addition to calculating tool path factors such as the line width and build height per layer, the oxygen content, hardness, density, and mechanical properties were determined for each experiment.