A review of laser engineered net shaping (LENS) build and process parameters of metallic parts

Izadi, Mojtaba; Farzaneh, Aidin; Mohammed, Mazher Iqbal; Gibson, Ian; Rolfe, Bernard

doi:10.1108/rpj-04-2018-0088

Cited by 87 publications

(32 citation statements)

References 110 publications

(190 reference statements)

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“…5) Stage scanning: the substrate placed on an X-Y stage, which was computer programmed to move and form any predefined patterns. The operation principle of the system was similar to the laser beam directed energy deposition (LB-DED) processes; [9,56,57] however, the major difference here was the in situ and on-demand formation of nanoscale building blocks.…”

Section: Methodsmentioning

confidence: 99%

Additive Nanomanufacturing of Multifunctional Materials and Patterned Structures: A Novel Laser‐Based Dry Printing Process

Ahmadi

Lee

Unocic

et al. 2021

Adv Materials Technologies

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Direct printing of functional materials, structures, and devices on various platforms such as flexible to rigid substrates is of interest for applications ranging from electronics to energy and sensing to biomedical devices. Current additive manufacturing (AM) and printing processes are either limited by the available sources of functional materials or require to be in the form of precisely designed inks. Here, a novel laser‐based additive nanomanufacturing (ANM) system capable of in situ and on‐demand generations of nanoparticles that can serve as nanoscale building blocks for real‐time sintering and dry printing a variety of multifunctional materials and patterns at atmospheric pressure and room temperature is reported. The ability to print different functional materials on various rigid and flexible platforms is shown. This nonequilibrium process involves pulsed laser ablation of targets and in situ formation of pure amorphous nanoparticles’ stream that are guided through a nozzle onto the surface of the substrate, where they are sintered/crystallized in real‐time. Further, the process–structure relationship of the printed materials from nanoscale to microscale is shown. This new ANM concept opens up an opportunity for printing advanced functional materials and devices on rigid and flexible substrates that can be employed both on the earth and in space.

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Section: Methodsmentioning

confidence: 99%

Additive Nanomanufacturing of Multifunctional Materials and Patterned Structures: A Novel Laser‐Based Dry Printing Process

Ahmadi

Lee

Unocic

et al. 2021

Adv Materials Technologies

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“…It shows the reality of being able to transfer three-dimensional (3D) designs created on computers to a machine that can replicate the geometry into a physical object. This can all be done almost regardless of the geometrical complexity and without determining how each feature must be made and in what order (Murtezaoglu et al, 2018;Maurya et al, 2020;Izadi et al, 2020).…”

Section: Introductionmentioning

confidence: 99%

Additive manufacturing a powerful tool for the aerospace industry

Khorasani¹,

Ghasemi

Rolfe

et al. 2021

RPJ

Self Cite

178

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Purpose Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom, lightweight design, functional integration and rapid prototyping. In this paper, the authors show how AM can be implemented not only for prototyping but also production using different optimization approaches in design including topology optimization, support optimization and selection of part orientation and part consolidation. This paper aims to present how AM can reduce the production cost of complex components such as jet engine air manifold by optimizing the design. This case study also identifies a detailed feasibility analysis of the cost model for an air manifold of an Airbus jet engine using various strategies, such as computer numerical control machining, printing with standard support structures and support optimization. Design/methodology/approach Parameters that affect the production price of the air manifold such as machining, printing (process), feedstock, labor and post-processing costs were calculated and compared to find the best manufacturing strategy. Findings Results showed that AM can solve a range of problems and improve production by customization, rapid prototyping and geometrical freedom. This case study showed that 49%–58% of the cost is related to pre- and post-processing when using laser-based powder bed fusion to produce the air manifold. However, the cost of pre- and post-processing when using machining is 32%–35% of the total production costs. The results of this research can assist successful enterprises, such as aerospace, automotive and medical, in successfully turning toward AM technology. Originality/value Important factors such as validity, feasibility and limitations, pre-processing and monitoring, are discussed to show how a process chain can be controlled and run efficiently. Reproducibility of the process chain is debated to ensure the quality of mass production lines. Post-processing and qualification of the AM parts are also discussed to show how to satisfy the demands on standards (for surface quality and dimensional accuracy), safety, quality and certification. The original contribution of this paper is identifying the main production costs of complex components using both conventional and AM.

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“…Contrary to the conventional subtractive technologies, the manufacture of LMD parts takes place by adding material layer by layer through the injection of fresh metal powder particles into a locally created melt pool by means of a constant interaction between a high intensity laser source and a solid metal surface. When the melt pool moves, a solid metal bead takes form thanks to the rapid cooling of the molten material, allowing a sound bonding between the as deposited material and the underlying surface [ 6 ]. The absence of cutting tools and the limited Heat Affected Zone (HAZ) generated during the deposition process allow LMD to be particularly suitable for the manufacturing and repairing of Inconel 718 components, enabling the production of optimized and complex industrially driven geometrical shapes by means of a more efficient management and use of the raw material [ 5 ].…”

Section: Introductionmentioning

confidence: 99%

Laser Metal Deposition of Inconel 718 Alloy and As-built Mechanical Properties Compared to Casting

et al. 2021

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In the last years, powder-based Laser Metal Deposition (LMD) has been attracting attention as a disruptive Additive Manufacturing (AM) technique for both the fabrication and restoration of Inconel 718 components, enabling to overcome current limitations faced by conventional manufacturing processes in terms of manufacturing costs, tool wear, and lead time. Nevertheless, the uncertainty related to the final mechanical performance of the as-built LMD parts limits a wider adoption of such technology at industrial level. This research work focuses on the mechanical characterization of as-built Inconel 718 specimens through split Hopkinson tensile bar tests performed at different strain rate conditions. The influence of laser power on the final mechanical behavior of the as-built tensile samples is discussed and compared with the mechanical response of as-cast ones. The as-built specimens exhibit a high internal density (i.e., 99.92% and 99.90% for 300 W and 400 W, respectively) and a more ductile behavior compared to the as-cast ones for every evaluated strain rate condition. The strain hardening capacity of the as-built samples increases with the laser power involved in the LMD process, reaching an average Yield Strength of 703 MPa for specimens realized at 400 W and tested at 800/s.

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A review of laser engineered net shaping (LENS) build and process parameters of metallic parts

Cited by 87 publications

References 110 publications

Additive Nanomanufacturing of Multifunctional Materials and Patterned Structures: A Novel Laser‐Based Dry Printing Process

Additive Nanomanufacturing of Multifunctional Materials and Patterned Structures: A Novel Laser‐Based Dry Printing Process

Additive manufacturing a powerful tool for the aerospace industry

Laser Metal Deposition of Inconel 718 Alloy and As-built Mechanical Properties Compared to Casting

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