Abstract
Metal additive manufacturing (AM) has several similarities to conventional metal manufacturing, such as welding and cladding. During the manufacturing process, both metal AM and welding experience repeated partial melting and cooling, referred to as deposition. Owing to deposition, metal AM and welded products often share common product quality issues, such as layer misalignment, dimensional errors, and residual stress generation. This paper comprehensively reviews the similarities in quality monitoring methods between metal AM and conventional metal manufacturing. It was observed that a number of quality monitoring methods applied to metal AM and welding are interrelated; therefore, they can be used complementarily with each other.
Highlights
Metal additive manufacturing produces three-dimensional metal objects by repeatedly adding and solidifying metal materials layer by layer
This can interfere with the formation of smooth and precise welded surfaces, which are required in aerospace products to reduce weight and drag [50], introducing numerical studies on cladding track formation in metal additive manufacturing (AM) processes may be promising for welding
This paper comprehensively reviewed the similarities between metal AM and welding based on their principles, quality issues, and quality monitoring methods
Summary
Metal additive manufacturing (metal AM) produces three-dimensional metal objects by repeatedly adding and solidifying metal materials layer by layer. PBF and DED often experience common quality issues, such as layer misalignment, dimensional errors, and residual stress generation, owing to repeated melting and cooling. Such quality issues can be found in welding, one of the conventional metal manufacturing processes that utilize deposition. Undesirable plume and spatter infusing into the product often result in dimensional errors, undesirable surface quality, and a decrease splashes of molten metal or metal powders. Metal materials are b4ooifle15d by the high-energy input of the concentrated beam, and the boiled metal emits a plume and spatter during the process [21]. NNuummeerriiccaall QQuuaalliittyy MMoonniittoorriinngg MMeetthhooddss iinn MMeettaall AAMM aanndd WWeellddiinngg. NNuummeerriiccaall QQuuaalliittyy MMoonniittoorriinngg MMeetthhooddss iinn MMeettaall AAMM TfcafTcylyshlahaiienadnedgdcgddcSSliltaiietnaenhshdvvdgkgeedeedtrsctircrianrhlanlaaalagalcgdcdnpnkktdtudre.ur.aimi.aEmnEnccWlgklgekeCCrrtaitiisrihrchsncaaaeaaegaccliilkktkkteqrqrhhatguaguieaieaelealoltoltol.oiimamtaft[fyly2lt.ete.h6hmt[mt[]re2re2yoy5po5dd]n]nrtteeooqioqiptptpuoupoopooararrsrsiniseinenintetdtdtegegidiifididfccmimeatetmmddtete3hhetettDthethhethaaooededplld.d.iciocFmsFmsrrwioiioigegennsdsnunussemms-rsr-sreiiseo-eeoees44tcnntccaatsatasailliholhlloAAeoneoenrwMrMwmorroosfosfuhhrraaaalssaatssivssvoopiccienfefnhhhgtftgefeyhhoolmlmeseceeci-u-uaccafifctsslistlnianeieacmcdadaddololdodofopfpidinnnaarnreogogissilddddiitwnntureuergagnncaiccltltttcteheksisik----.. TThhee rreessuullttss sshhoowweedd tthhaatt tthhee ddeeppoossiitteedd aarreeaa uunnddeerr tthheesstatacckkeeddlalayyereruundnderewrwenetnrtarpaipdidtemtempepraertuatruerceycclyecsl,ews,hwichhicchoucloducldaucsaeurseesreidsuidaul asltrsetsrse.ssT.hTehreesriedsuidaul astlrsetsrsesins itnhethme emtaeltaAlMAMprpodroudcut cwt awsansunmuemriecrailclayllqyuqaunatinfiteifideidn ainsatusdtuydcyoncdonudctuecdtebdybRyoRbeorbtesretts aelt. a[3l.5[]3,5a]n, danidt witaws aosbosebrsveerdvetdhatthiantcirnecarseiansgintghethlaeylearyeorf torfatcrkacinkcirnecarseeadsetdhethaevearvaegreagreesriedsuidalusatlrsetsrse.sRs.enRkeennkeent aelt. a[l3.6[]3u6]seudseadnaunmuemriecrailcmalomdoedl teol itdoeindteifnytitfhyethinefliuneflnuceenocef hoefahtefalot wfloown othnethreesirdeusiadlusatrlesstsreisnsainDaEDDEpDropdruocdt.uTcth.rTouhgrohutghhe pthreopporsoepdosmeoddmelo, dtheel,atuhtehaoursthfooursnfdotuhnadt mthaaitnmtaianinintgaianicnognsatacnont lsatasenrtplaoswererpcoawueserdcaruessieddureaslidstureasl sstirnesths eincothmepcloemx-pshleaxp-eshdappreoddpurcot.dDuectn.lDinegnelrinegt earl.e[t3a7l].p[3r7o]pporsoepdoasenduma neruimcaelrpicraelpdricetdioicntiomnomdeoldfeolrfothrethreesriedsuidaul asltrsetsressasnadnddidstisotrotriotinonininmmuultlitpiplelelalayyeerrssooffccllaaddddiinngg ttrraacckkss,, wowobbhhssiieellerrevvttiihhnneeggllttaahhyyaaeettrrttbhbheeeellnonowewewwiillttyywwddaaeessppssoouussbibittjjeeeeddccttleleaaddyyeettoorr eeccxoxoppmmeepprriirreeeennssccsseieivvddeettshhstteerregegssrrssee..aatteesstt aammoouunntt ooff tteennssiillee ssttrreessss,, Process Metal AM
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