S. Ben Amor, Floriane Zongo, B. Louhichi, Antoine Tahan, V. Brailovski
Additive Manufacturing (AM) processes generate parts layer-by-layer without using formative tools. The resulting advantages highlight the capability of AM to become an inherent part of product development. However, process-specific challenges such as high surface roughness, the stair-stepping effect, or dimensional deviations inhibit the establishment of AM at the industrial scale. Thus, AM parts often need to be post-processed using established manufacturing processes. Many process parameters and geometrical factors influence the dimensional accuracy in AM. Published results relating to these deviations are also difficult to compare because they are based on several geometries that are manufactured using different processes, materials, and machine settings. Laser Powder Bed Fusion (LPBF) is gaining in popularity, but one of the obstacles facing its larger industrial use is the limited knowledge of its dimensional and geometrical performances. Therefore, using it requires studying the process and improving the accuracy of the parts involved. This paper represents a new attempt to predict dimensional deviations of LPBF parts. During the project, the scale- and material concentration-related phenomena were implemented in a new image analysis model and applied to the as-built part. We carried out a comparison between the results of the proposed model with those obtained from numerical analyses and experiments. The model does not use finite element analysis, takes less time to compute, and provides reasonable prediction accuracy.
{"title":"Dimensional Deviation Prediction Model Based on Scale and Material Concentration Effects for LPBF Process","authors":"S. Ben Amor, Floriane Zongo, B. Louhichi, Antoine Tahan, V. Brailovski","doi":"10.1115/iam2022-93969","DOIUrl":"https://doi.org/10.1115/iam2022-93969","url":null,"abstract":"\u0000 Additive Manufacturing (AM) processes generate parts layer-by-layer without using formative tools. The resulting advantages highlight the capability of AM to become an inherent part of product development. However, process-specific challenges such as high surface roughness, the stair-stepping effect, or dimensional deviations inhibit the establishment of AM at the industrial scale. Thus, AM parts often need to be post-processed using established manufacturing processes. Many process parameters and geometrical factors influence the dimensional accuracy in AM. Published results relating to these deviations are also difficult to compare because they are based on several geometries that are manufactured using different processes, materials, and machine settings. Laser Powder Bed Fusion (LPBF) is gaining in popularity, but one of the obstacles facing its larger industrial use is the limited knowledge of its dimensional and geometrical performances. Therefore, using it requires studying the process and improving the accuracy of the parts involved. This paper represents a new attempt to predict dimensional deviations of LPBF parts. During the project, the scale- and material concentration-related phenomena were implemented in a new image analysis model and applied to the as-built part. We carried out a comparison between the results of the proposed model with those obtained from numerical analyses and experiments. The model does not use finite element analysis, takes less time to compute, and provides reasonable prediction accuracy.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"29 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128298913","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
H. Nguyen, Hawke Suen, B. Poudel, Z. Qu, Mohsan Uddin Ahmad, P. Kwon, A. Benard, Haseung Chung
Haynes 214 high temperature heat exchanger assembly with enclosed heat flow channels and internal fin structures was successfully fabricated using our scalable and expeditious additive manufacturing (SEAM) process, a new metal additive manufacturing (AM) technology developed at Michigan State University (MSU). Three dimensional green objects can be fabricated by selectively photopolymerizing Haynes 214 metal suspension on a powder bed system in a layer-by-layer fashion. An innovative strategy to attain a complete binder removal and high density as well as dimensional accuracy were developed and employed to achieve final metal parts with relative density above 99.5% and no geometrical distortion.
{"title":"From Photopolymerization of Metal Suspension to Practical and Economical Additive Manufacturing of Haynes 214 Alloy for High Temperature Application","authors":"H. Nguyen, Hawke Suen, B. Poudel, Z. Qu, Mohsan Uddin Ahmad, P. Kwon, A. Benard, Haseung Chung","doi":"10.1115/iam2022-93984","DOIUrl":"https://doi.org/10.1115/iam2022-93984","url":null,"abstract":"\u0000 Haynes 214 high temperature heat exchanger assembly with enclosed heat flow channels and internal fin structures was successfully fabricated using our scalable and expeditious additive manufacturing (SEAM) process, a new metal additive manufacturing (AM) technology developed at Michigan State University (MSU). Three dimensional green objects can be fabricated by selectively photopolymerizing Haynes 214 metal suspension on a powder bed system in a layer-by-layer fashion. An innovative strategy to attain a complete binder removal and high density as well as dimensional accuracy were developed and employed to achieve final metal parts with relative density above 99.5% and no geometrical distortion.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128531691","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Autonomous construction systems (ACSs) have become a topic of great interest in recent years in a variety of areas, including design, materials science, architecture, space exploration, natural disaster recover, military operations, and others. Several different approaches have been proposed, the most promising (and so far most widely-applied) one being a large-scale system based on additive manufacturing (or 3-D printing) principles, where a concrete- or foam-based material is extruded in layers to produce a structure. This structure may be used as a basic shell around which a useful building, shelter, bridge, extraterrestrial habitat, or other infrastructure can be built or may be able to produce a full building in one operation. This article extracts information about the the major components, sub-systems, and interfaces in these systems from a broad sampling of published literature and uses this information to propose a quasi-general system architecture and identify design opportunities. These models can be used to drive further research efforts on these systems, assist with more agile implementation, and improve the design of large-scale 3-D printing-based systems. This work is a first step in the development of a reliable general system architecture similar to those used in the design of large-scale military and aerospace systems.
{"title":"System Architecture and Design Parameters for Extrusion-Based Autonomous Construction Systems","authors":"A. Patterson, Bhaskar Vajipeyajula, W. Norris","doi":"10.1115/iam2022-93884","DOIUrl":"https://doi.org/10.1115/iam2022-93884","url":null,"abstract":"\u0000 Autonomous construction systems (ACSs) have become a topic of great interest in recent years in a variety of areas, including design, materials science, architecture, space exploration, natural disaster recover, military operations, and others. Several different approaches have been proposed, the most promising (and so far most widely-applied) one being a large-scale system based on additive manufacturing (or 3-D printing) principles, where a concrete- or foam-based material is extruded in layers to produce a structure. This structure may be used as a basic shell around which a useful building, shelter, bridge, extraterrestrial habitat, or other infrastructure can be built or may be able to produce a full building in one operation. This article extracts information about the the major components, sub-systems, and interfaces in these systems from a broad sampling of published literature and uses this information to propose a quasi-general system architecture and identify design opportunities. These models can be used to drive further research efforts on these systems, assist with more agile implementation, and improve the design of large-scale 3-D printing-based systems. This work is a first step in the development of a reliable general system architecture similar to those used in the design of large-scale military and aerospace systems.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"79 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128584545","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In developing the wire + arc additive manufacturing (WAAM) process for creep resistant alloys for defence applications, structures were built from nickel-based superalloy Rene 41 (RE41). The performance of the additive manufactured alloy was analysed for applications including components used in high-speed flight environments, where external structures could reach service temperatures of up to 1000 K. As a single use system with relatively short flight times of < 1 hour, components will be highly stressed to minimise structural mass. In this paper, three wall structures were deposited using a plasma transferred arc process, in a layer-by-layer manner where each layer was mechanically worked by machine hammer peening directly after deposition. With a constant impact frequency, three different travel speeds for the peening tool were used for each wall structure. To understand the most effective cold working parameters, samples were tested and analysed for their mechanical properties and microstructural characteristics after aging treatment. Samples were tested at room temperature and compared with results of both non-worked heat-treated AM material and wrought data obtained from literature review. Heat-treated only material showed a typical dendritic structure with large columnar grains, and peened material showed a significantly different grain structure. No noticeable difference was observed in the formed phases between the two conditions. Mechanical testing showed promising results with a significant improvement over the non-worked strength. Intermediate and slow peening speeds were very effective, achieving UTS and YS results close to that of the wrought alloy, with a similar increase in the elastic modulus compared to non-worked material. However, faster peening speeds were less effective at returning the material to wrought strength.
{"title":"In-Process Mechanical Working of Additive Manufactured Rene 41","authors":"Will James, S. Ganguly, G. Pardal","doi":"10.1115/iam2022-94060","DOIUrl":"https://doi.org/10.1115/iam2022-94060","url":null,"abstract":"\u0000 In developing the wire + arc additive manufacturing (WAAM) process for creep resistant alloys for defence applications, structures were built from nickel-based superalloy Rene 41 (RE41). The performance of the additive manufactured alloy was analysed for applications including components used in high-speed flight environments, where external structures could reach service temperatures of up to 1000 K. As a single use system with relatively short flight times of < 1 hour, components will be highly stressed to minimise structural mass. In this paper, three wall structures were deposited using a plasma transferred arc process, in a layer-by-layer manner where each layer was mechanically worked by machine hammer peening directly after deposition. With a constant impact frequency, three different travel speeds for the peening tool were used for each wall structure. To understand the most effective cold working parameters, samples were tested and analysed for their mechanical properties and microstructural characteristics after aging treatment. Samples were tested at room temperature and compared with results of both non-worked heat-treated AM material and wrought data obtained from literature review.\u0000 Heat-treated only material showed a typical dendritic structure with large columnar grains, and peened material showed a significantly different grain structure. No noticeable difference was observed in the formed phases between the two conditions. Mechanical testing showed promising results with a significant improvement over the non-worked strength. Intermediate and slow peening speeds were very effective, achieving UTS and YS results close to that of the wrought alloy, with a similar increase in the elastic modulus compared to non-worked material. However, faster peening speeds were less effective at returning the material to wrought strength.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"83 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126276570","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shreehard Sahu, B. Kumar, S. Sahoo, B. N. Jaya, D. Srinivasan
Co based superalloy Mar M 509 having excellent high temperature oxidation and hot corrosion resistance is studied via the laser powder bed fusion (LPBF) process. The microstructure and mechanical properties of Mar M 509 in the as-printed (AsP) and heat-treated (HT) condition are compared, as a function of two build orientations (longitudinal (L) and transverse (T)), to establish a working range for application of the alloy. The AsP condition has a distinct cellular microstructure (500–600 nm) with 50–60 nm carbide particles decorating the cell boundaries. The L build orientation displays a strong <001> texture, has columnar grains with a grain size of 8–35 μm (along major axis) and a grain aspect ratio of 4, while the T orientation displays a more equiaxed, but bi-modal microstructure with a grain size of 5–28 μm. The room temperature mechanical properties show variability between L and T with T having 15% higher hardness and 34% higher 0.2% yield strength (YS), 30% lower elongation than L. After a short cycle heat treatment at 1250°C, the weld bead structure and cellular boundaries are broken down and there is substantial grain growth in both L (25–33 μm along major axis) and T orientations (5–42 μm), along with coarsening of carbides (250–350 nm). The dislocation density reduces substantially, indicating recrystallisation, and the lattice parameter of the matrix drops significantly, suggesting solute depletion that contributes to precipitate growth and enrichment of the carbides. There is a drop in the yield strength from 860 MPa to 740 MPa in L and from 1150 MPa to 840MPa in T and an increase in ductility from 14% to 23% in L.
{"title":"Thermal Stability of Additively Manufactured Mar M 509","authors":"Shreehard Sahu, B. Kumar, S. Sahoo, B. N. Jaya, D. Srinivasan","doi":"10.1115/iam2022-91410","DOIUrl":"https://doi.org/10.1115/iam2022-91410","url":null,"abstract":"\u0000 Co based superalloy Mar M 509 having excellent high temperature oxidation and hot corrosion resistance is studied via the laser powder bed fusion (LPBF) process. The microstructure and mechanical properties of Mar M 509 in the as-printed (AsP) and heat-treated (HT) condition are compared, as a function of two build orientations (longitudinal (L) and transverse (T)), to establish a working range for application of the alloy. The AsP condition has a distinct cellular microstructure (500–600 nm) with 50–60 nm carbide particles decorating the cell boundaries. The L build orientation displays a strong <001> texture, has columnar grains with a grain size of 8–35 μm (along major axis) and a grain aspect ratio of 4, while the T orientation displays a more equiaxed, but bi-modal microstructure with a grain size of 5–28 μm. The room temperature mechanical properties show variability between L and T with T having 15% higher hardness and 34% higher 0.2% yield strength (YS), 30% lower elongation than L. After a short cycle heat treatment at 1250°C, the weld bead structure and cellular boundaries are broken down and there is substantial grain growth in both L (25–33 μm along major axis) and T orientations (5–42 μm), along with coarsening of carbides (250–350 nm). The dislocation density reduces substantially, indicating recrystallisation, and the lattice parameter of the matrix drops significantly, suggesting solute depletion that contributes to precipitate growth and enrichment of the carbides. There is a drop in the yield strength from 860 MPa to 740 MPa in L and from 1150 MPa to 840MPa in T and an increase in ductility from 14% to 23% in L.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"25 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114472047","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Anup Kulkarni, Vivek C. Peddiraju, S. Chatterjee, D. Srinivasan
The current work presents an understanding of microstructure and mechanical properties as a function of build geometry and build orientation in Cu-Cr-Zr via the laser powder bed fusion (LPBF) technique. Porosity, microstructure, and mechanical properties have been compared in the as-printed (AP) and heat treated (HT) LPBF Cu-Cr-Zr, between cylindrical and cube geometries, along the longitudinal (L) and transverse (T) build orientations. Varying porosity levels were observed that yielded parts with 96–97% relative density in the AP condition. The AP microstructure, characterized by a combination of optical and electron microscopic techniques, demonstrated a hierarchical microstructure, comprising of grains (2.5–100 μm) with a cellular substructure (400–850 nm) and intracellular nanoscale (20–60 nm) precipitates enriched in Cu and Zr. Unlike most materials in the AP condition, crystallographic texture was found to be absent; however, very distinct river like patterns highlighted a novel characteristic of the LPBF Cu-Cr-Zr. Upon solutionizing and aging, Cr precipitates were seen heterogeneously nucleating along cell boundaries (0.5–1.3 μm), causing up to 45% enhancement in the strength and a 4–5% lower ductility. The yield strength along the transverse orientation was 10–16% higher than that of longitudinal orientation, in both the AP and HT conditions. Fracture surface of the tensile samples exhibited micro-voids and cleavage facets and unmelted particles. In spite of the observed defects, the overall mechanical properties matched well with those obtained in nearly dense (> 99%) samples and the mechanical property debit was less than 10%.
{"title":"Effect of Build Geometry and Porosity in Additively Manufactured CuCrZr","authors":"Anup Kulkarni, Vivek C. Peddiraju, S. Chatterjee, D. Srinivasan","doi":"10.1115/iam2022-93986","DOIUrl":"https://doi.org/10.1115/iam2022-93986","url":null,"abstract":"\u0000 The current work presents an understanding of microstructure and mechanical properties as a function of build geometry and build orientation in Cu-Cr-Zr via the laser powder bed fusion (LPBF) technique. Porosity, microstructure, and mechanical properties have been compared in the as-printed (AP) and heat treated (HT) LPBF Cu-Cr-Zr, between cylindrical and cube geometries, along the longitudinal (L) and transverse (T) build orientations. Varying porosity levels were observed that yielded parts with 96–97% relative density in the AP condition. The AP microstructure, characterized by a combination of optical and electron microscopic techniques, demonstrated a hierarchical microstructure, comprising of grains (2.5–100 μm) with a cellular substructure (400–850 nm) and intracellular nanoscale (20–60 nm) precipitates enriched in Cu and Zr. Unlike most materials in the AP condition, crystallographic texture was found to be absent; however, very distinct river like patterns highlighted a novel characteristic of the LPBF Cu-Cr-Zr. Upon solutionizing and aging, Cr precipitates were seen heterogeneously nucleating along cell boundaries (0.5–1.3 μm), causing up to 45% enhancement in the strength and a 4–5% lower ductility. The yield strength along the transverse orientation was 10–16% higher than that of longitudinal orientation, in both the AP and HT conditions. Fracture surface of the tensile samples exhibited micro-voids and cleavage facets and unmelted particles. In spite of the observed defects, the overall mechanical properties matched well with those obtained in nearly dense (> 99%) samples and the mechanical property debit was less than 10%.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"37 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129303613","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
E. Nandha Kumar, K. Athira, S. Chatterjee, D. Srinivasan
Additive manufacturing of high gamma prime (γ’) Nickel-based superalloys are challenging due to their hot cracking tendency. This study comprises an understanding of microstructural evolution and mechanical properties of Inconel 939 (IN939) alloy processed via laser powder bed fusion (LPBF). The as-printed samples comprised of columnar grains along the build direction with a pronounced <100> texture resulting in ∼17% lower elastic modulus along the build direction as compared to the builds in transverse orientation. The microstructure consists of cellular and columnar dendrites with segregation of Nb, Ta and Si in the inter-dendritic regions (decorating the cell boundaries). Occurrence of fine (< 50 nm) intra granular carbides in the as printed condition is a unique feature of this microstructure. Heat treatment resulted in dissolution of the dendritic microstructure with precipitation of semi-coherent γ’ (Ni3(Al,Ti)) precipitates (150–200 nm) homogeneously from the matrix resulting in ∼16% enhanced yield strength. The <100> texture is retained even after the solution and aging heat treatment indicating thermal stability of this structure.
{"title":"Effect of Heat Treatment on Structure and Properties of Laser Powder Bed Fusion Inconel 939","authors":"E. Nandha Kumar, K. Athira, S. Chatterjee, D. Srinivasan","doi":"10.1115/iam2022-93945","DOIUrl":"https://doi.org/10.1115/iam2022-93945","url":null,"abstract":"\u0000 Additive manufacturing of high gamma prime (γ’) Nickel-based superalloys are challenging due to their hot cracking tendency. This study comprises an understanding of microstructural evolution and mechanical properties of Inconel 939 (IN939) alloy processed via laser powder bed fusion (LPBF). The as-printed samples comprised of columnar grains along the build direction with a pronounced <100> texture resulting in ∼17% lower elastic modulus along the build direction as compared to the builds in transverse orientation. The microstructure consists of cellular and columnar dendrites with segregation of Nb, Ta and Si in the inter-dendritic regions (decorating the cell boundaries). Occurrence of fine (< 50 nm) intra granular carbides in the as printed condition is a unique feature of this microstructure. Heat treatment resulted in dissolution of the dendritic microstructure with precipitation of semi-coherent γ’ (Ni3(Al,Ti)) precipitates (150–200 nm) homogeneously from the matrix resulting in ∼16% enhanced yield strength. The <100> texture is retained even after the solution and aging heat treatment indicating thermal stability of this structure.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"52 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127004079","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Gustavo Melo, Rohit Ravi, Lucas Jauer, J. Schleifenbaum
Additive Manufacturing (AM) has a great potential of disrupting product design and supply chains in many industries by means of its unique capabilities when compared to traditional manufacturing. A wide range of designers would like to take advantage of AM to improve their designs, but they need assistance in learning and breaking out of their conventional manufacturing mindset in the early phases of the design process. Therefore, this study explores the use of Augmented Reality (AR) to enhance the learning experience of the existing Design Heuristics for Additive Manufacturing using Design for Additive Manufacturing (DfAM) cards. In this study, we propose a modification of DfAM cards to include AR markers into the existing card design and hence provide a comprehensive visualization along with the information about heuristics and examples on the DfAM cards. This helps the user to understand the real-world structure of the final printed product before it is printed. The cross-platform game engine Unity is used for developing the AR models for this research. We also investigate the advantages that AR can provide as a visual interface. An expert review is conducted to obtain development feedback and a trial training session with students is carried out. The student evaluated positively the use of the AR app in their DfAM lecture and exercise.
{"title":"Exploring Augmented Reality for Teaching Design for Additive Manufacturing","authors":"Gustavo Melo, Rohit Ravi, Lucas Jauer, J. Schleifenbaum","doi":"10.1115/iam2022-94406","DOIUrl":"https://doi.org/10.1115/iam2022-94406","url":null,"abstract":"\u0000 Additive Manufacturing (AM) has a great potential of disrupting product design and supply chains in many industries by means of its unique capabilities when compared to traditional manufacturing. A wide range of designers would like to take advantage of AM to improve their designs, but they need assistance in learning and breaking out of their conventional manufacturing mindset in the early phases of the design process. Therefore, this study explores the use of Augmented Reality (AR) to enhance the learning experience of the existing Design Heuristics for Additive Manufacturing using Design for Additive Manufacturing (DfAM) cards. In this study, we propose a modification of DfAM cards to include AR markers into the existing card design and hence provide a comprehensive visualization along with the information about heuristics and examples on the DfAM cards. This helps the user to understand the real-world structure of the final printed product before it is printed. The cross-platform game engine Unity is used for developing the AR models for this research. We also investigate the advantages that AR can provide as a visual interface. An expert review is conducted to obtain development feedback and a trial training session with students is carried out. The student evaluated positively the use of the AR app in their DfAM lecture and exercise.","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"141 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124691450","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
J. Pereira, F. Zubiri, David Aguilar, M. C. Taboada, G. Guillonneau, J. Rocchi
Nickel-based NiCrSiFeB alloy (Ni-Cr-Si-B self-fluxing family) are excellent candidates for replacing Cobalt-based alloys in aeronautical components such as sealing rings, valve seats, sliding bearing seats, etc. In this type of components, commonly manufactured by centrifugal casting and conventional processes, high temperature wear and stiffness under complex thermo-mechanical stresses cause lack of sealing and an increase in the wear rate. Metal additive manufacturing by direct laser metal deposition with powder (p-LMD) is presented as a potential manufacturing route for the complex processing of this type of alloys. This research work deals with the development of a new manufacturing route using p-LMD that ranges from the proper selection of the chemical composition for the starting powders, the development of the LMD process parameters to tackle the challenges associated to the wide solidification range and crack susceptibility of Ni-Cr-Si-B alloys, its monitoring and control, as well as the post-processing required to achieve the manufacture of aeronautical components. In this work, the porosity analysis, as-built microstructure, hardness at room temperature and at high temperature, and the strengthening mechanisms have been studied in cylinders manufactured with different chemical composition grades and LMD process parameter sets (slow, normal and fast deposition speed).
{"title":"Development of a New Manufacturing Route by Direct Laser Metal Deposition With NiCrSiFeB Alloys to Replace Cobalt in Aeronautical Components","authors":"J. Pereira, F. Zubiri, David Aguilar, M. C. Taboada, G. Guillonneau, J. Rocchi","doi":"10.1115/iam2022-91705","DOIUrl":"https://doi.org/10.1115/iam2022-91705","url":null,"abstract":"\u0000 Nickel-based NiCrSiFeB alloy (Ni-Cr-Si-B self-fluxing family) are excellent candidates for replacing Cobalt-based alloys in aeronautical components such as sealing rings, valve seats, sliding bearing seats, etc. In this type of components, commonly manufactured by centrifugal casting and conventional processes, high temperature wear and stiffness under complex thermo-mechanical stresses cause lack of sealing and an increase in the wear rate. Metal additive manufacturing by direct laser metal deposition with powder (p-LMD) is presented as a potential manufacturing route for the complex processing of this type of alloys. This research work deals with the development of a new manufacturing route using p-LMD that ranges from the proper selection of the chemical composition for the starting powders, the development of the LMD process parameters to tackle the challenges associated to the wide solidification range and crack susceptibility of Ni-Cr-Si-B alloys, its monitoring and control, as well as the post-processing required to achieve the manufacture of aeronautical components. In this work, the porosity analysis, as-built microstructure, hardness at room temperature and at high temperature, and the strengthening mechanisms have been studied in cylinders manufactured with different chemical composition grades and LMD process parameter sets (slow, normal and fast deposition speed).","PeriodicalId":184278,"journal":{"name":"2022 International Additive Manufacturing Conference","volume":"56 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2022-10-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"131111588","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zongchen Li, Andre Gut, I. Burda, S. Michel, Dejan Romančuk, C. Affolter
Additive manufacturing techniques have made AM Ti-6Al-4V parts a reality in many industries. However, despite the optimism, their poor fatigue performance especially in high cycle regime is the major hurdle for the industry accepting it as mainstream. One of the reasons owes to the widely distributed internal defects inherent to the AM process, which create a hotbed for fatigue crack initiation. Available investigations on lack of fusions, regarded as the most detrimental defects, are very limited. Regarding this, we conducted finite element analysis to evaluate the fatigue performance of Ti-6Al-4V alloys with an individual lack-of-fusion defect. Three different lack-of-fusion defects, directly scanned from Selective Laser Melting Ti-6Al-4V coupons using Micro-Computed Tomography with different geometry features, have been numerically analyzed. We compare the mechanical results (e.g., stress, strain, and elastic stress concentration factors) of the lack-of-fusion defects to the results of gas-entrapped pores, which share the same height and the same volume, to reveal the detriment of lack-of-fusion defects. Furthermore, we conduct a parametric study on lack-of-fusion defects orientation and size, as well as the aspect ratios. The results provide a better understanding of the mechanical behavior of the lack-of-fusion defects in additive manufactured Ti-6Al-4V alloys, paving the way for further research of additive manufactured metallic alloys.
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