Feasibility Of Additive Manufacturing Research Articles

Structural analysis of selective laser melted copper-tin alloy

Additively manufactured complex geometries from copper alloys with high thermal and mechanical properties have drawn the attention of researchers. The present contribution explores the additive manufacturing (AM) of copper-based alloys from powder particles intended for heat sink and heat exchange applications. Selective laser melting (SLM) parameters featuring low laser beam power (160 W), moderate scanning speed (320 mm/s), and high energy density (200 J/mm³) were employed to fabricate dense components from CuSn10 particles. The present work deal with structural analysis and precision investigation of microfabrication, particularly in Struts, Tubes, and Fins. Mechanical properties (compression and hardness) for Strut structure, differential pressure evaluations for Tube structure, and analyses of thermal and electrical conductivities for Fin structure were investigated. The results showed an improvement in strength compared to those of pure copper, facilitating ease of AM. The obtained results affirm the feasibility of AM, demonstrating the successful creation of complex and combined solid-porous structures using SLM process from Cu alloys. A comprehensive structural investigation and characterization of the Cu–Sn alloy is presented here, aiming to establish a standardized approach for analysing Cu alloys. The results indicate that small-scaled structures fabricated via CuSn10 alloy exhibits a thermal conductivity of 34.3 W·m⁻¹·K⁻¹, an electrical conductivity of 4.72×10⁶ S/m, a hardness of 119 HV-50, a uniform surface roughness of 6 µm, and can withstand a force loading of 1 kN.

Evaluation of geometrical precision and surface roughness quality for the additively manufactured radio frequency quadrupole prototype

A multidisciplinary collaboration within the I.FAST project teamed-up to develop additive manufacturing (AM) technology solutions for accelerators. The first prototype of an AM pure-copper Radio Frequency Quadrupole (RFQ) has been produced, corresponding to ¼ of a 4-vane RFQ. It was optimised for production with state-of-the-art laser powder bed fusion technology. Geometrical precision and roughness of the critical surfaces were measured. Although the obtained values were beyond standard RFQ specifications, these first results are promising and confirmed the feasibility of AM manufactured complex copper accelerator cavities. Therefore, further post-processing trials have been conducted with the sample RFQ to improve surface roughness. Algorithms for the AM technological processes have also been improved, allowing for higher geometrical precision. This resulted in the design of a full 4-vane RFQ prototype. At the time of the paper submission the full-size RFQ is being manufactured and will undergo through the stringent surface quality measurements. This paper is discussing novel technological developments, is providing an evaluation of the obtained surface roughness and geometrical precision as well as outlining the potential post-processing scenarios along with future tests plans.

Additive Manufacturing of Slow-Moving Automotive Spare Parts: A Supply Chain Cost Assessment

This study develops a cost model for the additive manufacturing (AM)-produced spare parts supply chain in the automotive industry. Moreover, we evaluate the economic feasibility of AM for slow-moving automotive spare parts by comparing the costs of the traditional manufacturing (TM) spare parts supply chain (SPSC) with centralized, outsourced AM SPSC. Data from a multiple case study of an OEM in the automotive industry regarding SPSC is utilized. The supply chain costs of 14 individual spare parts were analyzed, and the total SPSC cost for the AM and TM, were compared. Three of the fourteen parts showed potential for cost-savings, if they were produced with AM instead of TM. In this context, AM polymer parts showed greater potential than metal to replace TM as the more economical option of manufacturing from a total supply chain cost perspective. This study shows that the AM competitiveness to TM, from a financial perspective, increases for spare parts with low demand, high minimum order quantity, and high TM production price. The SPSC cost model included: cost of production, transport, warehousing, and service costs. This study contributes to the emerging field of part identification for AM and the existing literature regarding cost modeling in SPSCs.

Pitting corrosion resistance of additive manufactured alloy 718 in alkaline brines at elevated temperatures

AbstractThe feasibility of additive manufacturing (AM) to produce industrial components, also for the oil and gas industry, has been demonstrated in the past. Therefore, current research efforts focus on demonstrating the reliability of AM materials subjected to demanding service conditions. In this regard, special attention has been paid to its corrosion resistance in harsh environments as one of the most critical properties in these applications. The beneficial combination of high strength, excellent thermal stability, and outstanding corrosion resistance makes alloy 718 (UNS N07718) the most used wrought and AM nickel alloy in the oil and gas industry. Wrought 718 has an extensive record of field performance in demanding oil and gas applications including directional drilling tools that undergo extreme mechanical loads in corrosive drilling fluids. On the other hand, limited data regarding the corrosion behavior of AM718 in typical drilling environments has been collected so far. In this research work, the pitting susceptibility of selective laser melted alloy 718 in simulated drilling environments has been studied. Open circuit potential measurements as well as cyclic potentiodynamic and potentiostatic polarization tests were used to characterize the pitting corrosion resistance of AM718 in alkaline brines at elevated temperatures. In addition, microstructural particularities in alloy 718 were investigated to explain the observed differences in the electrochemical behaviors.

Comparison of Additively Manufactured and Machined Antenna Array Performance at Ka-Band

Additive manufacturing (AM) is a rapidly developing field, which potentially decreases the manufacturing costs and enables increasingly complex antenna shapes. Metal-based AM might be particularly useful for manufacturing antennas at millimeter-wave (mm-wave) range, because these antennas are physically small enough making AM cost efficient, and manufacturing accuracy could still suffice for good electrical performance. In this letter, two additively manufactured and identical machined fully metallic <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">$Ka$</tex-math></inline-formula> -band Vivaldi antenna arrays are compared. The manufactured antenna arrays are compared using RF measurements to conclude the feasibility of AM for manufacturing antenna arrays at mm-wave frequencies. Comparison of the measured radiation patterns and realized gains of each of the antenna arrays between 26 and 40 GHz shows close to identical radiation patterns for all the arrays. A loss in realized gain of 0.5–1.5 dB is observed in the AM arrays when compared to the machined array due to the used materials and the surface roughness.

First Proof-of-Concept Prototype of an Additive Manufactured Radio Frequency Quadrupole

Continuous developments in additive manufacturing (AM) technology are opening up opportunities in novel machining, and improving design alternatives for modern particle accelerator components. One of the most critical, complex, and delicate accelerator elements to manufacture and assemble is the radio frequency quadrupole (RFQ) linear accelerator, which is used as an injector for all large modern proton and ion accelerator systems. For this reason, the RFQ has been selected by a wide European collaboration participating in the AM developments of the I.FAST (Innovation Fostering in Accelerator Science and Technology) Horizon 2020 project. The RFQ is as an excellent candidate to show how sophisticated pure copper accelerator components can be manufactured by AM and how their functionalities can be boosted by this evolving technology. To show the feasibility of the AM process, a prototype RFQ section has been designed, corresponding to one-quarter of a 750 MHz 4-vane RFQ, which was optimised for production with state-of-the-art laser powder bed fusion (L-PBF) technology, and then manufactured in pure copper. To the best of the authors’ knowledge, this is the first RFQ section manufactured in the world by AM. Subsequently, geometrical precision and surface roughness of the prototype were measured. The results obtained are encouraging and confirm the feasibility of AM manufactured high-tech accelerator components. It has been also confirmed that the RFQ geometry, particularly the critical electrode modulation and the complex cooling channels, can be successfully realised thanks to the opportunities provided by the AM technology. Further prototypes will aim to improve surface roughness and to test vacuum properties. In parallel, laboratory measurements will start to test and improve the voltage holding properties of AM manufactured electrode samples.

Comparison of CAD systems for generative design for use with additive manufacturing

As a reaction to the increasing market dynamics and complex requirements, today’s products need to be developed quickly and customized to the customer’s individual needs. In the past, CAD systems are mainly used to visualize the model that the product designer creates. Generative Design shifts the task of the CAD program by actively participating in the shaping process. This results in more design options and the complexity of the shapes and geometries increases significantly. This potential can be optimally exploited through the combination of Generative Design with Additive Manufacturing (AM). Artificial intelligence and the input of target parameters generate geometries, for example, by creating material for stressed areas, which in turn develops biomorphic shapes and thus significantly reduces the consumption of resources. This contribution aims at the evaluation of existing applications in CAD systems for generative design. Special attention is paid to the requirements in design education and easy access for students. For this purpose, three representative CAD systems are selected and analyzed with the help of a comprehensive example of mass reduction. The aim is to perform an individual result analysis in order to assess the application based on various criteria. By using different materials, the influence of the material for the generation is investigated by comparing the material distribution. By comparing the generated models, differences of the CAD systems can be identified and possible fields of application can be presented. By specifying the manufacturing parameters for the generation of the models, the feasibility of AM can be guaranteed without having to modify the results. The physical implementation of the example by means of Fused Deposition Modeling demonstrates this in an exemplary way and examines the interface of the Generative Design and AM. The results of this contribution will enable an evaluation of the different CAD systems for Generative Design according to technical, visual and economic aspects.

Experimental Assessment of a 3D-Printed Stainless Steel Gas Foil Bearing

Abstract Gas foil bearings (GFBs) are a key enabling technology for high-speed turbomachinery. The manufacturing of GFBs relies mainly on sheet metal forming techniques in order to conceive the compliant structure (e.g., bump foil) and the top foil. Such techniques require the development of a special know-how and most importantly, limit the design creativity to what is manufacturable using sheet metal forming. Additive manufacturing (AM) is a disruptive technology in prototyping and fabrication. This paper accesses the feasibility of AM in the fabrication of GFBs using selective laser melting (SLM) technology. A stainless steel GFB is 3D-printed in one piece, including the sleeve, the bump, and top foils. The bearing is assessed geometrically and statically before being tested on a gas bearing test rig, where it supported a ø40 mm rotor (m = 2 kg). The bearing performed similar to a conventional GFB, showing rotordynamically stable and repeatable operation up to 37.5 krpm. Such result highlights the potentials of AM as a viable alternative for foil bearing manufacturing.

Case study on AM of an IN718 aircraft component using the LMD process

When manufacturing components from forged blanks of nickel-based super alloys, companies have to cope with rising prices, long delivery time as well as cost intense machining. In this case Additive Manufacturing (AM) can provide an alternative solution. To prove the feasibility of AM, an aircraft engine mounting component was successfully built up by Laser Material Deposition (LMD) from Inconel 718 powder. Due to the length of 500 mm and its complex structure, the pylon bracket component is demanding to build up by LMD. Investigations on process and build-up strategy development as well as analysis of deformation behaviour have been performed.

A decision support method for evaluation and process selection of Additive Manufacturing

Additive Manufacturing (AM) is still immature in most application areas. Lack of knowledge among potential users is a key barrier for AM uptake. There is therefore a significant need for methods, frameworks and tools that will enable potential users to effectively identify if AM would fit their specific case, and subsequently select the right AM process for their needs. This work aims at presenting a framework and a method for assisting potential users in the evaluation and eventual uptake of AM. The framework comprises three discreet levels. Level 1 regards self-evaluation of different AM technologies, replying to the question of AM being potentially beneficial for a specific use case. At Level 2, the framework validates the technical feasibility of AM for a specific part, supporting the user towards deciding the appropriate AM technologies for his specific use case. Level 3 is addressing manufacturability issues, by analyzing the design and proposing manufacturing of certain features with a combination of additive and subtractive manufacturing where necessary.

Additive manufacturing of biomedical implants: A feasibility assessment via supply-chain cost analysis

The adoption of additive manufacturing (AM) for fabricating biomedical implants at hospitals provides many potential benefits. Relative to biomedical implants fabricated via traditional manufacturing (TM), typically available by suppliers out of the immediate region, biomedical implants fabricated through AM provides an opportunity to receive more patient-specific, customized parts with faster response, a lower inventory level, and reduced delivery costs. Despite the promising features of AM technologies, the make-or-buy decisions are not straightforward and require careful investigation due to the relatively high AM machine and production costs. Most of the existing studies focus on the analysis of process-level costs, which are usually evaluated/calculated based on individual AM processes. No research efforts, to the best of our knowledge, have been dedicated to the quantitative analysis of the costs of supply chains integrated with AM facilities, e.g., inventory cost, transportation cost, product lead time, etc. In this study, we propose a stochastic cost model to quantify the supply-chain level costs associated with the production of biomedical implants using AM techniques, and investigate the economic feasibility of using such technologies to fabricate biomedical implants at the sites of hospitals. The problem is formulated in the form of a stochastic programming model, which determines the number of AM facilities to be established and volume of product flow between manufacturing facilities and hospitals. A customized Sample Average Algorithm (SAA) is developed to obtain the solutions. We apply the cost model to a real-world case study that focuses on the use of biomedical implants for hospitals in the state of Mississippi (MS), and identify the conditions and cost parameters that have significant impact on the economic feasibility of AM. We find that the ratio between the unit production costs of AM and TM (ATR), as well as product lead time and demands, are key cost parameters that determine the economic feasibility of AM.

A Metallurgical Evaluation of the Powder-Bed Laser Additive Manufactured 4140 Steel Material

Using laser powder bed fusion (PBF-L) additive manufacturing (AM) process for steel or iron powder has been attempted for decades. This work used a medium carbon steel (AISI 4140) powder to explore the feasibility of AM. The high carbon equivalent of 4140 steel (CEIIW ≈ 0.83) has a strong tendency toward cold cracking. As such, the process parameters must be carefully controlled to ensure the AM build quality. Through an orthogonally designed experimental matrix, a laser-welding procedure was successfully developed to produce 4140 steel AM builds with no welding defects. In addition, the microstructure and micro-cleanliness of the as-welded PBF-L AM builds were also examined. The results showed an ultra-fine martensite lath structure and an ultra-clean internal quality with minimal oxide inclusion distribution. After optimizing the PBF-L AM process parameters, including the laser power and scan speed, the as-welded AM builds yielded an average tensile strength higher than 1482 MPa and an average 33 J Charpy V-notch impact toughness at −18°C. The surface quality, tensile strength, and Charpy V-notch impact toughness of AM builds were comparable to the wrought 4140 steel. The excellent mechanical properties of 4140 steel builds created by the PBF-L AM AM process make industrial production more feasible, which shows great potential for application in the aerospace, automobile, and machinery industries.

Dry metal forming of high alloy steel using laser generated aluminum bronze tools

Regarding the optimization of forming technology in economic and environmental aspects, avoiding lubricants is an approach to realize the vision of a new green technology. The resulting direct contact between the tool and the sheet in non-lubricated deep drawing causes higher stress and depends mainly on the material combination. The tribological system in dry sliding has to be assessed by means on the one hand of the resulting friction coefficient and on the other hand of the wear of the tool and sheet material. The potential to generate tailored tribological systems for dry metal forming could be shown within the investigations by using different material combinations and by applying different laser cladding process parameters. Furthermore, the feasibility of additive manufacturing of a deep drawing tool was demonstrated. The tool was successfully applied to form circular cups in a dry metal forming process.