Download or read book The Assessment and Optimization of Parameters to Automate Plasma Based Additive Manufacturing of Ti 6Al 4v Components for Standardized Test Vehicle written by Christopher Owino Ng`Anya and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: The Plasma metal deposition (PMD) process, is a technology employed at RHP Technology Company, Austria.PMD is a branch of the Wire Arc Additive manufacturing (WAAM) method that uses the Direct Energy Deposition technique. The wire material is directly melted by heat generated from the Plasma, incident on the substrate. Its high deposition rate and cost-effectiveness make the process attractive for manufacturers. This study aimed to assess optimum process parameter that yields high mechanical properties responses using Ti-6Al-4V material, highest layer growth, automate the machine processing system, and eliminate challenges associated with the selection of the right process parameters that can produce better quality geometries. Three input parameters (current,Travel speed, and wire feed rate).The larger the better was applied to optimize the two main responses.The Fuzzy logic experiments were conducted to assess the initial process parameters while Taguchi L16OA and Grey Relation were employed in the design of experiments and for response optimization purposes.A four-level value of current,Travel speed,and Wire feed speed process parameters were selected for an L-shaped main wall geometry 130 and 110 mm in length with a width of 10mm using fuzzy logic parameters. A total height of 65mm with the deposition of 48 layers of seam was achieved.The results in the middle part of the wall showed the lowest hardness compared to other parts of the wall while other mechanical properties such as Tensile reduced with layer growth.These results were attributed to mainly the thermal gradient between the layers during deposition. The Current and wire feed speeds were found the main effect on the quality of geometry*****The Plasma metal deposition (PMD) process, is a technology employed at RHP Technology Company, Austria.PMD is a branch of the Wire Arc Additive manufacturing (WAAM) method that uses the Direct Energy Deposition technique. The wire material is directly melted by heat g

Download or read book Laser Based Additive Manufacturing of Metal Parts written by Linkan Bian and published by CRC Press. This book was released on 2017-08-09 with total page 422 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser-Based Additive Manufacturing (LBAM) technologies, hailed by some as the "third industrial revolution," can increase product performance, while reducing time-to-market and manufacturing costs. This book is a comprehensive look at new technologies in LBAM of metal parts, covering topics such as mechanical properties, microstructural features, thermal behavior and solidification, process parameters, optimization and control, uncertainty quantification, and more. The book is aimed at addressing the needs of a diverse cross-section of engineers and professionals.

Download or read book Build Strategy Investigation of Ti 6Al 4V Produced Via a Hybrid Additive Manufacturing Process written by Lei Yan and published by . This book was released on 2019 with total page 57 pages. Available in PDF, EPUB and Kindle. Book excerpt: "Till now, laser metal deposition (LMD) has been developed with the capability of near-net shape high-performance metal parts fabrication, especially complicated titanium alloys, nickel alloys, and aluminum alloys. However, LMD processed parts usually do not meet end-use requirements without post treatments. In-process part quality inspection and inner features machining are impossible within a single LMD process. Hybrid additive manufacturing (HAM), which integrates additive and subtractive manufacturing in one process, has been proposed to increase the feasibility of complex parts fabrication. This dissertation aims to improve the applications of Ti-6Al-4V parts fabricated via a HAM technique. The first research topic is to investigate the build strategy using the HAM process of correlating yield strength of final parts to processing parameters from both additive and subtractive processes for Ti-6Al-4V structures. The second research topic focuses on coolant residue cleaning methods, where effective cleaning methods have been generated on both oil- and water-based coolant. To reduce trial-and-error efforts and optimize large-scale parts fabrication using HAM, thermal control has become an essential factor that directly relates to the final distortion and residual stress. Hence, the third research topic is conducted on the fast prediction of thermal history in large-scale parts fabrication via a HAM process. This dissertation leads to new knowledge for the effective fabrication of metallic components via a HAM process. Moreover, the research results of the dissertation could benefit a wide range of industries"--Abstract, page iv.

Download or read book Residual Stress in Plasma Transferred Arc PTA of Ti 6Al 4V for Additive Manufacturing AM written by Hadi Moztarzadeh and published by . This book was released on 2020 with total page pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Laser Additive Manufacturing of Metallic Materials and Components written by Dongdong Gu and published by Elsevier. This book was released on 2022-12-07 with total page 824 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser Additive Manufacturing of Metallic Materials and Components discusses the current state and future development of laser additive manufacturing technologies, detailing material, structure, process and performance. The book explores the fundamental scientific theories and technical principles behind the elements of laser additive manufacturing, touching upon scientific and technological challenges faced by laser additive manufacturing technology. This book is suitable for those who want to further "understand and "master laser additive manufacturing technology and will expose readers to innovative industrial applications that meet significant demand from aeronautical and astronautical high-end modern industries for low-cost, short-cycle and net-shape manufacturing of structure-function integrated metallic components. With the increasing use of industrial applications, additive manufacturing processes are deepening, with technology continuing to evolve. As new scientific and technological challenges emerge, there is a need for an interdisciplinary and comprehensive discussion of material preparation and forming, structure design and optimization, laser process and its control, microstructure and performance characterization, and innovative industrial applications, hence this book covers these important aspects. - Highlights an integration of material, structure, process and performance for laser additive manufacturing of metallic components to reflect the interdisciplinary nature of this technology - Covers cross-scale structure and performance coordination mechanisms, including micro-scale material microstructure control, meso-scale interaction between laser beam and particle matter, and macro-scale precise forming of components and performance control - Explores fundamental scientific theories and technical principles behind laser additive manufacturing processes - Provides innovation elements and strategies for the future sustainable development of additive manufacturing technologies in terms of multi-materials design, novel bio-inspired structure design, tailored printing process with meso-scale monitoring, and high-performance and functionality of printed components

Download or read book Laser Additive Manufacturing written by Milan Brandt and published by Woodhead Publishing. This book was released on 2016-09-01 with total page 500 pages. Available in PDF, EPUB and Kindle. Book excerpt: Laser Additive Manufacturing: Materials, Design, Technologies, and Applications provides the latest information on this highly efficient method of layer-based manufacturing using metals, plastics, or composite materials. The technology is particularly suitable for the production of complex components with high precision for a range of industries, including aerospace, automotive, and medical engineering. This book provides a comprehensive review of the technology and its range of applications. Part One looks at materials suitable for laser AM processes, with Part Two discussing design strategies for AM. Parts Three and Four review the most widely-used AM technique, powder bed fusion (PBF) and discuss other AM techniques, such as directed energy deposition, sheet lamination, jetting techniques, extrusion techniques, and vat photopolymerization. The final section explores the range of applications of laser AM. Provides a comprehensive one-volume overview of advances in laser additive manufacturing Presents detailed coverage of the latest techniques used for laser additive manufacturing Reviews both established and emerging areas of application

Download or read book Additive Manufacturing Technology written by Kun Zhou and published by John Wiley & Sons. This book was released on 2023-02-28 with total page 405 pages. Available in PDF, EPUB and Kindle. Book excerpt: Highly comprehensive resource covering all key aspects of the current developments of additive manufacturing Additive Manufacturing Technology: Design, Optimization, and Modeling provides comprehensive and in-depth knowledge of the latest advances in various additive manufacturing technologies for polymeric materials, metals, multi-materials, functionally graded materials, and cell-laden bio-inks. It also details the application of numerical modeling in facilitating the design and optimization of materials, processes, and printed parts in additive manufacturing. The topics covered in this book include: Fundamentals and applications of 4D printing, 3D bioprinting of cell-laden bio-inks, and multi-material additive manufacturing Alloy design for metal additive manufacturing, mechanisms of metallurgical defect formation, and the mechanical properties of printed alloys Modified inherent strain method for the rapid prediction of residual stress and distortion within parts fabricated by additive manufacturing Modeling of the different stages in polymer and metal additive manufacturing processes, including powder spreading, melting, and thermal stress evolution By providing extensive coverage of highly relevant concepts and important topics in the field of additive manufacturing, this book highlights its essential role in Industry 4.0 and serves as a valuable resource for scientists, engineers, and students in materials science, engineering, and biomedicine.

Download or read book Microstructural Analysis of TI 6Al 4V Components Made by Electron Beam Additive Manufacturing written by Rashadd Coleman and published by . This book was released on 2017 with total page 95 pages. Available in PDF, EPUB and Kindle. Book excerpt: Electron Beam Additive Manufacturing (EBAM) is a relatively new additive manufacturing (AM) technology that uses a high-energy electron beam to melt and fuse powders to build full-density parts in a layer by layer fashion. EBAM can fabricate metallic components, particularly, of complex shapes, in an efficient and cost-effective manner compared to conventional manufacturing means. EBAM is an enabling technology for rapid manufacturing (RM) of metallic components, and thus, can efficiently integrate the design and manufacturing of aerospace components. However, EBAM for aerospace-related applications remain limited because the effect of the EBAM process on part characteristics is not fully understood. In this study, various techniques including microhardness, optical microscopy (OM), X-ray diffraction (XRD), Scanning Electron Microscopy (SEM), and electron backscatter diffraction (EBSD) were used to characterize Ti-6Al-4V components processed using EBAM. The results were compared to Ti-6Al-4V components processed using conventional techniques. In this study it is shown that EBAM built Ti-64 components have increased hardness, elastic modulus, and yield strength compared to wrought Ti-6Al-4V. Further, it is also shown in this study that the horizontal build EBAM Ti-6Al-4V has increased hardness, elastic modulus, and yield strength compared to vertical build EBAM due to a preferential growth of the [Beta] phase.

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 A Geometry Based Approach Towards Improving the Structural Integrity of Single walled Ti6al4v Alloy Features Fabricated Using Laser Directed Energy Deposition Additive Manufacturing written by Darshan Thakkar and published by . This book was released on 2020 with total page 59 pages. Available in PDF, EPUB and Kindle. Book excerpt: Presence of sharp turns in the deposition tool-path for Additive Manufacturing (AM) introduces heterogeneity in built-part thereby affecting structural integrity. Slower deposition speeds around turn points or corner leads to defects such as increased wall thickness, porosity, lack of fusion voids, and cracks. Such defects can be minimized by either by optimizing processing parameters or through geometry optimization. Optimizing processing parameters requires extensive and expensive set of experiments. Furthermore, it is challenging to accurately model the process and have closed loop controls because of the impracticality to include all process parameters. This work focuses on optimizing the geometry instead of process parameters to fabricate components with minimum defects. In this work, single walled cubical Ti6Al4V shells with sharp and rounded corners were fabricated using laser Directed Energy Deposition (DED). Cross sectional and build plane coupons were extracted from each sample for microstructure and defect analysis. Results show that inclusion of rounded corners leads to consistent deposition speeds. Defect density measurements, using optical microscope, show reduction of defects from 6.8 ± 0.35% to a virtually defect-free structure for samples with rounded corners. Results indicate that consistent deposition speed around rounded corners improved homogeneity in the resulting microstructure.

Download or read book Parameter Optimization for Controlling Aluminum Loss when Laser Depositing Ti 6Al 4V written by Richard Charles Barclay and published by . This book was released on 2013 with total page 46 pages. Available in PDF, EPUB and Kindle. Book excerpt: "The ability to predict the mechanical properties of engineering materials is crucial to the manufacturing of advanced products. In the aerospace industry, Ti-6Al-4V is commonly used to build structures. Any deviation from the alloy's standard properties can prove detrimental. Thus, the compositional integrity of the material must be controlled. The ability to directly build and repair large, complicated structures directly from CAD files is highly sought after. Laser Metal Deposition (LMD) technology has the potential to deliver that ability. Before this process can gain widespread acceptance, however, a set of process parameters must be established that yield finished parts of consistent chemical composition. This research aims to establish such a set of parameters. Design of Experiments was utilized to maximize the information gained while minimizing the number of experimental trials required. A randomized, two-factor experiment was designed, performed, and replicated. Another set of experiments (nearly identical to the first) was then performed. The first set of experiments was completed in an open environment, while the second set was performed in an argon chamber. Energy Dispersive X-Ray Spectroscopy (EDS) was then used to perform a quantitative microanalysis to determine the aluminum level in each sample. Regression analysis was performed on the results to determine the factors of importance. Finally, fit plots and response surface curves were used to determine an optimal parameter set (process window). The process window was established to allow for consistent chemical composition of laser deposited Ti64 parts"--Abstract, page iii.

Download or read book The Influence of Manufacturing Parameters on Properties of Ti 6Al 4V Products Fabricated by Selective Laser Melting and Their Surface Coating with Bioactive Polymer written by Snehashis Pal and published by . This book was released on 2019 with total page 300 pages. Available in PDF, EPUB and Kindle. Book excerpt:

Download or read book Image Processing based Techniques for Process Parameter Characterization in Plasma Transferred Arc Additive Manufacturing PTA AM Process written by Raviraj Gajbhiye and published by . This book was released on 2022 with total page 0 pages. Available in PDF, EPUB and Kindle. Book excerpt: The plasma transferred arc additive manufacturing (PTA-AM) process is a recently established additive manufacturing (AM) technique for manufacturing large parts for the resource industries. In the PTA-AM process, the build quality of the 3D part is governed by various processing parameters, including but not limited to plasma arc current, stand-off distance (SOD) and powder flow rate. The PTA-AM is challenging for in-process monitoring due to the complex interaction among the plasma arc, powder stream and substrate. Any instability in these processing parameters affects the overall build quality of the component, inducing non-conformance to geometrical properties. In the AM field, various high-speed imaging techniques are used to investigate the correlation between the processing parameter variation contributing to quality fluctuations of the final 3D product. This thesis presents the in-situ image processing methodologies to quantify and analyze the process aspects of the emergent PTA-AM system. Firstly, the single-track multi-layer bead deposition experiments of WC-reinforced NiCrBSi composites are carried out on a PTA-AM system and recorded with a high-speed camera. The optimized SOD has been determined from image analysis, contributing to the uniform deposition with quality deviation. The image analyzed SOD is validated with the experimentally determined SOD. This information is also used to evaluate the impact of powder variation on bead layer height. Secondly, the proposed in-situ image processing technique has been employed to describe the relationship between powder stream distribution and build geometry variation. In addition, the effect of plasma arc current on bead layer geometry (height and width) is also investigated. The Analysis of variance and t-tests has checked the significance of build quality dependence on powder and plasma arc variation. It is well-known that the powder flow behaviour (the particle trajectories and velocities) under the plasma arc region is a complex but crucial physical phenomenon that affects the geometric dimensions and the bead deposition characteristics in PTA-AM. Therefore, we proposed another image processing methodology to investigate the powder stream behaviour under the influence of the plasma arc region. In the findings, variation in trajectories and impact velocities of individual powder particles due to plasma arc has been observed. Using the single-particle trajectory model, we validated that the results are within the theoretical range. Later, based on calculated impact velocities of powder particles, the parametric study was conducted to predict the spreading and solidification of molten powder particles on the substrate. Using dimensionless numbers, the parametric effect of hydrodynamic forces (Weber and Reynolds number) and thermophysical forces (Stefan and Peclet number) on the impinging melted powder particles is also studied.

Download or read book Microstructural Characterizations and Modeling of Ti 6Al 4V Parts Made by Electron Beam Additive Manufacturing EBAM written by Xibing Gong and published by . This book was released on 2014 with total page 148 pages. Available in PDF, EPUB and Kindle. Book excerpt:

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 Additive Manufacturing Laser Deposition of Ti 6Al 4V for Aerospace Repair Application written by Nanda Kumar Dey and published by . This book was released on 2014 with total page 59 pages. Available in PDF, EPUB and Kindle. Book excerpt: "Parts or products machined from high performance metals are very expensive, partly due to the processing complexities during manufacturing. Therefore, many high performance metal parts users, such as the aerospace industry, mold/die casting industry, heavy machinery consumers etc., extend the service of these damaged parts by employing repair or remanufacturing technology. The research objective is to use laser deposition and machining processes to repair titanium parts. This thesis discusses a new way of approach for developing a repair process for Ti-6Al-4V for the aerospace industry using Laser Metal Deposition (LMD). The repairs were conducted in a multi-axis hybrid manufacturing systems in which the laser deposition and the machining processes are integrated. The study broadly included preparing the defects, laser deposition, machining, sample preparations and mechanical tests. Comparative study of mechanical properties (UTS, YS, percentage elongation) of the repaired samples to the ideal conditions was undertaken. The research throws up interesting facts where the data from the test sample shows enhancement of properties of the repaired part."--Abstract, page iv.

Download or read book Characterization of Ti 6Al 4V Produced Via Electron Beam Additive Manufacturing written by Brian J. Hayes and published by . This book was released on 2015 with total page 65 pages. Available in PDF, EPUB and Kindle. Book excerpt: