Abstract
Hybrid Metal Extrusion & Bonding Additive Manufacturing (HYB-AM) is a hybrid manufacturing technology for the deposition of layered metal structures. This new deposition process is a complex metal forming operation, yet there is significant lack of knowledge regarding the governing mechanisms. In this work, we have used finite element analysis (FEA) to study material flow in the extruder, as well as the conditions at the interfaces of the deposited extrudate and the substrate, aiming to identify and characterize the process parameters involved. Analysis of the material flow shows that the extrusion pressure is virtually independent of the deposition rate. Furthermore, from the simulations of the material deposition sequence, it is clearly visible how the contact pressure at the interface will drop below the bonding threshold if the feed speed is too high relative to the material flow through the die. The reduced pressure also leads to the formation of a ‘gas-pocket’ inside the die, thus further degrading the conditions for bonding. The analyses of the process have provided valuable insights for the further development and industrialization of the process.
Highlights
Hybrid Metal Extrusion and Bonding Additive Manufacturing (HYB-AM) is a new solid-state additive manufacturing process for the fabrication of layered 3D metal structures [1,2]
In HYB-AM, the feedstock material is processed through a continuous rotary extruder, which serves the purpose of dispersing oxides and providing pressure for bonding to occur between the extrudate and the substrate
Based on the finite element analysis (FEA) results obtained in this study, the following conclusion can be made for the pressure-generating mechanism: 1
Summary
Hybrid Metal Extrusion and Bonding Additive Manufacturing (HYB-AM) is a new solid-state additive manufacturing process for the fabrication of layered 3D metal structures [1,2]. The process operates in the solid-state, meaning that defects associated with melting of the feedstock material are avoided. The low heat input enables high deposition rates when compared to the melted-state AM-process. In HYB-AM, the feedstock material is processed through a continuous rotary extruder, which serves the purpose of dispersing oxides and providing pressure for bonding to occur between the extrudate and the substrate. The die is scraping the substrate to remove surface oxides as the feedstock material is deposited in a stringer-by-stringer manner to form layers. The part needs to be post-processed by traditional subtractive machining to obtain the desired net-shape.
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