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Additive Manufacturing (AM) technology enables the production of personalized goods at reduced development costs, shorter lead times, lower energy consumption during manufacturing, and decreased material waste. AM will be consolidated as a leading technology in numerous sectors in the near future due to the maturity of the technology, the wide range of possibilities afforded by 3D printing, and the institutional push. One of the most important aspects of Industry 4.0 is 3D printing. It may be used to fabricate complicated parts and allows companies to cut inventory, develop on-demand items, create smaller localized manufacturing conditions, and even shorten supply chains. AM is expected to increase rapidly in the future because of its above stated remarkable “performance record.“ According to a report published the AM market is predicted to produce US$2 trillion worth of components and end products by year 2030. Hence integration of smart technology and production systems or indirectly one can say that AM is promoting Industry 4.0 and it plays a pivotal role in solving some of the 4th industrial revolution’s most important needs. AM is a future paradigm for futuristic production systems, and Industry 4.0 will leverage its potential to reach essential goals. AM will be found now days in a variety of industrial applications including aerospace and health care to consumer goods. This review article discusses about brief AM technology, history, its industrial applications, challenges, and future prospective. Finally, case studies using AM has been considered.

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In the present research work, microstructural evolution and corrosion behaviour of the high-velocity oxy-fuel (HVOF) sprayed Alloy718-nano Al 2 O 3 composite coatings were examined. These coatings were deposited on the grey cast iron (C.I) substrate. The agglomerated nano-Al 2 O 3 reinforcement particles in three different proportions (10, 20 & 30 wt.%) were varied in the Alloy718 based matrix to develop the composite coatings. Corrosion testing of bare and coated samples was carried out at an ambient temperature in the NaCl solution (3.5 wt.%) using the potentiodynamic polarization technique. The polarization resistance (Rp), the corrosion efficiency and the corrosion rate (CR) were measured for the developed coatings and substrate. The surface morphology of as-sprayed and corroded coatings was studied using scanning electron microscopy coupled with energy-dispersive spectroscopy. X-ray diffraction analysis was conducted to determine the different phases present in the feedstock powders and as-sprayed coatings. The as-sprayed coatings were seen with nano-Al 2 O 3 particles uniformly embedded in the melted Alloy718 matrix. The coating with 30 wt.% nano-Al 2 O 3 particles revealed the maximum microhardness of about 1296±21 HV 0.2 compared to other coatings. The results showed that the corrosion resistance of the composite coatings increases with the increase in alumina particles in the Alloy718 matrix. The 30 wt.% alumina coating showed maximum resistance to corrosion due to the maximum decrease in the electrochemically active area associated with this coating.

Purpose In the present study, Al2O3 coatings were deposited on stainless steel AISI-304 material by using atmospheric plasma spraying technique to combat high temperature solid particle erosion. The present aims at the performance analysis of Al2O3 coatings at high temperature conditions. Design/methodology/approach The erosion studies were carried out at a temperature of 400°C by using a hot air-jet erosion tester for 30° and 90° impingement angles. The possible erosion mechanisms were analyzed from scanning electron microscope (SEM) micrographs. Surface characterization of the powder and coatings were conducted by using an X-ray diffractometer, SEM, equipped with an energy dispersive X-ray analyzer. The porosity, surface roughness and micro-hardness of the as-sprayed coating were measured. This paper discusses outcomes of the commonly used thermal spray technology, namely, the plasma spray method to provide protection against erosion. Findings The plasma spraying method was used to successfully deposit Al2O3 coating onto the AISI 304 substrate material. Detailed microstructural and mechanical investigations were carried out to understand the structure-property correlations. Major findings were summarized as under: the erosive wear test results indicate that the plasma sprayed coating could protect the substrate at both 30° and 90° impact angles. The coating shows better resistance at an impact angle of 30° compared with 90°, which is related to the pinning and shielding effect of the alumina particle. The major erosion wear mechanisms of Al2O3 coating were micro-cutting, micro-ploughing, splat removal and detachment of Al2O3 hard particles. Originality/value In the current study, the authors have followed the standard testing method of hot air jet erosion test as per American society for testing of materials G76-02 standard and reported the erosion behavior of the eroded samples. The coating was not removed at all even after the erosion test duration i.e. 10 min. The erosion test was continued till 3 h to understand the evolution of coatings and the same has been explained in the erosion mechanism. The outcome of the present study may be used to minimize the high temperature erosion of AISI-304 substrate.