Abstract
An additive manufacturing process should produce repeatable results as far as the properties of the material and the geometric dimensions that have to be adopted by a company as a production method are concerned. This represents a challenge for such high-volume sectors as the automotive industry, where quality and reliability are extremely important. One way of addressing this challenge is to qualify the process. A common framework has here been identified starting from the analysis of the factors that influence the stability of the result in the main phases of metal powder bed fusion (PBF) processes. A qualification procedure (QP), which offers possible solutions to help reduce risk factors, has been proposed. This procedure is independent of the industrial sectors, of which type of materials and metal PBF processes, and of the manufacturer of the used PBF system.
Highlights
Additive manufacturing (AM) has existed for decades and has already revolutionized the production of polymeric material components, new additive manufacturing (AM) technology developments are providing industries with the possibility of building structural components with a variety of metal alloys, ceramics, and composite materials
The contribution of this study is to identify the critical points of the powder bed fusion (PBF) processes through the analysis of the various phases to create a qualification procedure (QP)
AM dental implants are an example of this strategy: The shape of implants is not modified when changing from conventional casting or milling processes to AM
Summary
Additive manufacturing (AM) has existed for decades and has already revolutionized the production of polymeric material components, new AM technology developments are providing industries with the possibility of building structural components with a variety of metal alloys, ceramics, and composite materials. The AM technologies that are used for metal components include different production methods than can broadly be classified into two major groups: Powder bed fusion (PBF)-based technologies and directed energy deposition (DED)-based technologies. The process is repeated with successive layers of powder until the part is completely built These processes are generally known as selective laser melting (SLM) and electron beam melting (EBM). Unlike DED, which is generally used to add metallic material to existing metal parts, and for welding and repair applications, PBF processes allow complex geometries to be constructed. For this reason, PBF-based technologies are currently having a greater impact on many industrial sectors.
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