Additive Manufacturing in the Minerals, Metals, and Materials Community: Past, Present, and Exciting Future

Herderick, Edward D.

doi:10.1007/s11837-015-1799-4

Cited by 35 publications

(29 citation statements)

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“…In the spirit of providing the technical foundation for accelerating growth of AM, it is a great pleasure to present the 2017 follow-up installment to the special topic Progress in Additive Manufacturing. 11,12 Taken together, the papers here demonstrate deeper understanding of the depth and breadth of the AM field. They present work on a cross-section of processing routes including laser powder bed fusion, electron beam powder bed fusion, powder bed binder jetting, ultrasonic additive manufacturing, and fused deposition modeling.…”

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confidence: 52%

Accelerating the Additive Revolution

Herderick¹

2017

JOM

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The past year has seen accelerated growth and adoption of additive manufacturing (AM) by several measures, most notably in industrial adoption and implementation for materials intensive applications. Per the Wohlers Report 2016, the AM industry, consisting of all AM products and services worldwide, grew 25.9% (CAGR) to a total of US$5.165 billion in 2015.1 Further, sales of AM systems for manufacturing metal parts grew at a year-on-year rate of 46.9% for the most recent data available.1 This is reflective of greater interest and acceptance of the industrial manufacturing community for AM as a standard technique.This acceptance is the product of over 25 years of intensive research and development. Two early works of note include the first paper describing powder bed fusion AM in JOM in 1990, 2 in this case a polymeric wax and ABS materials. Similarly, the first description of using powder bed fusion AM for metals in Metallurgical and Materials Transactions A appeared in 1993, 3 in this case using intermetallic nickel-tin powder. Comparison of these early papers to recently published work 4 documenting fatigue evaluation of Ti-6Al-4V and nickel alloy 625, produced using commercially available powders and commercially available equipment, shows the progress that the materials processing community has driven and which serves as the foundation for accelerating growth in applications.The bedrock for this growth is the deeper understanding of the entire value stream for producing AM parts. For metal part production in the traditional manufacturing paradigm, a foundry provides material specifications to original equipment manufacturers consisting of the raw feedstock specification, cast properties, and forged ingot properties as applicable. In the new AM paradigm, the process looks quite different on first review. However, on deeper evaluation, the metal additive process qualification route follows the standard material intensive manufacturing route with specific elements modified per the process itself. The supplied powder is certified to specification, a fixed process is qualified, mechanical and chemical properties of interest are measured for the specific application, and an ongoing monitor for compliance is established. Post-machining, thermal processing, and non-destructive inspection and testing protocols specific to performance requirements are implemented just as in a performanceintensive weldment or cast component application. A critical role for the minerals, metals, and materials community is exploring and evaluating elements of the total process value stream and impacts on the microstructure and defect populations in relation to performance. Further, new characterization and non-destructive inspection methods tailored for complex AM-produced structures will be a key contribution by the community.The additive revolution is clearly accelerating, as evidenced by the growth in investment and industrial applications. As of this writing at the close of 2016, 40 CFM International LEAP-1A engines with AM-produced f...

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confidence: 52%

Accelerating the Additive Revolution

Herderick¹

2017

JOM

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“…Nowadays, these two techniques can be regarded as being basically the same, according to previous studies. [3][4][5][6] Both have the capability of building metal parts layer by layer, starting from a highly controlled metal powder. 7,8 The 3D computer-aided design model is initially split into several slices, individuating the cross sections corresponding to each slice.…”

Section: Introductionmentioning

confidence: 99%

Sensitivity of direct metal laser sintering Maraging steel fatigue strength to build orientation and allowance for machining

Croccolo

Agostinis

Fini

et al. 2018

Fatigue Fract Eng Mat Struct

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This work deals with the effect of build orientation and of allowance for machining on DMLS‐produced Maraging Steel MS1. The experimental results, arranged by tools of Design of Experiment, have been statistically processed and compared. The outcomes were that, probably due to effect of the thermal treatment, machining, and material properties, the aforementioned factors do not have a significant impact on the fatigue response. This made it possible to work out a global curve that accounts for all the results, consisting in a high amount of data points. This can be regarded as one of the most complete and reliable fatigue models in the current literature. Fractographic and micrographic studies have been performed as well, to individuate the crack initiation points, usually located at subsurface porosities, and to investigate the location of internal inclusions and the actual martensitic microstructure along the stacking direction and on the build plane.

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“…The final properties of the built parts, such as roughness, porosity, cracking propensity, and mechanical properties, depend on process parameters, such as laser power P (W), scanning speed Vs (mm/s), hatching distance Hd (µm) and layer thickness l (µm) [3][4][5][6][7][8]. These factors are important because re-melting depends on the amount of the volume energy density VED (J/mm 3 ) absorbed during the process [9], which is defined by the following equation: Results in this study will only be reported in VED and expressed in J/mm 3 . Cermets are composites material made of a hard refractory carbide embedded in a ductile metal binder matrix, usually cobalt matrix.…”

Section: Additive Manufacturing Of Cermet Produced By Laser Powder Be...mentioning

confidence: 99%

Additive manufacturing of cermet produced by laser powder bed fusion using alternative Ni binder

PAPY

2023

Materials Research Proceedings

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Abstract. Cermets are composite materials made of a ceramic reinforcement and a metal matrix, generally cobalt as binder, with mass content from 6 to 20 wt.%. Cermets are produced by conventional sintering process and are known for their high hardness, low friction coefficient, high wear resistance, and high melting temperature. Laser Powder Bed Fusion (L-PBF) is an additive manufacturing technology widely applied for direct fabrication of functional metallic parts with complex geometry such as internal channels or lattices structures. Considering several studies, production of cermets by L-PBF process is challenging. Recent publications have demonstrated the feasibility to produce WC-Co parts by L-PBF combined with Hot Isostatic Pressure (HIP) heat-treatment. HIP process is sometimes additionally performed as post-treatment to remove defects. HIP is performed at high temperatures and isostatic pressures in a furnace [1]. In this study, following an experimental design a parametric optimization was conducted in order to maximize the mass density of WC-17Ni. Process parameters were compared to those used for WC-17Co parts from recent study [2]. To improve the printed specimen integrity, the as-built samples were heat-treated. As-built and HIP samples were analyzed and compared in terms of mass density, microstructure, crystallographic phases, and macro hardness.

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Additive Manufacturing in the Minerals, Metals, and Materials Community: Past, Present, and Exciting Future

Cited by 35 publications

References 1 publication

Accelerating the Additive Revolution

Accelerating the Additive Revolution

Sensitivity of direct metal laser sintering Maraging steel fatigue strength to build orientation and allowance for machining

Additive manufacturing of cermet produced by laser powder bed fusion using alternative Ni binder

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