Direct additive manufacturing of metal parts for automotive applications

Zhao, Nanzhu; Parthasarathy, Mohan; Patil, Sandeep P.; Coates, David; Myers, Kyle J.; Zhu, Hanyu; Li, Wei

doi:10.1016/j.jmsy.2023.04.008

Cited by 52 publications

(12 citation statements)

References 16 publications

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“…In the biomedical sector, various types of metallic prostheses, bone regeneration scaffolds, or tissue engineering have been developed [ 5 , 6 , 7 ]. On the other hand, a significant number of components manufactured through AM have been implemented in the automotive industry, reducing costs and weight [ 8 , 9 ]. Furthermore, even the production of more efficient and complex energy batteries is now possible thanks to AM [ 10 , 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining

Monzón,

Bordón,

Paz

et al. 2024

Materials

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The combination of Atomic Diffusion Additive Manufacturing (ADAM) and traditional CNC machining allows manufacturers to leverage the advantages of both technologies in the production of functional metal parts. This study presents the methodological development of hybrid manufacturing for solid copper parts, initially produced using ADAM technology and subsequently machined using a 5-axis CNC system. The ADAM technology was dimensionally characterized by adapting and manufacturing the seven types of test artifacts standardized by ISO/ASTM 52902:2019. The results showed that slender geometries suffered warpage and detachment during sintering despite complying with the design guidelines. ADAM technology undersizes cylinders and oversizes circular holes and linear lengths. In terms of roughness, the lowest results were obtained for horizontal flat surfaces, while 15° inclined surfaces exhibited the highest roughness due to the stair-stepping effect. The dimensional deviation results for each type of geometry were used to determine the specific and global oversize factors necessary to compensate for major dimensional defects. This also involved generating appropriate over-thicknesses for subsequent CNC machining. The experimental validation of this process, conducted on a validation part, demonstrated final deviations lower than 0.5% with respect to the desired final part, affirming the feasibility of achieving copper parts with a high degree of dimensional accuracy through the hybridization of ADAM and CNC machining technologies.

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Section: Introductionmentioning

confidence: 99%

Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining

Monzón,

Bordón,

Paz

et al. 2024

Materials

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“…Due to the layer-by-layer accumulation of materials, the production process is nearly net forming, which can reduce the wastage of materials and improve the utilization rate of materials. AM technology is widely used in medical, 2,3 transportation, 4 aviation 5,6 and other fields. However, during the printing process, metal AM parts may present many material discontinuities 7 which affect the quality of the parts.…”

Section: Introductionmentioning

confidence: 99%

The semi-quantitative analysis of hole defects in metal additive manufacturing components using LIBS

Lin,

Hao,

Yang

et al. 2024

J. Anal. At. Spectrom.

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“…are the main advantages of metal AM processes over conventional subtractive technologies. [1,2,9] Among different AM methods, the wire arc additive manufacturing (WAAM) process has attracted special attention in recent years due to its ability to manufacture large-scale components. [10][11][12][13][14] Various types of metals such as low-carbon and low-alloy steels [7,[15][16][17][18][19] and Ni-, [16,[20][21][22][23] Al-, [4,24,25] and Ti-based alloys [10,23] are used as feedstock materials.…”

Section: Introductionmentioning

confidence: 99%

Effects of Heat Treatment on Microstructure and Properties of 347 Stainless Steel Alloy Prepared by Wire Arc Additive Manufacturing

Yadegar,

Sharifitabar,

Shafiee Afarani

2023

steel research int.

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In this study, 347 austenitic stainless steel parts were made by wire arc additive manufacturing process. Then, the effects of solution heat treatment at 1150°C for 3h followed by NbC stabilizing heat treatment at 950°C for 1h on the properties of the alloy were investigated. Results showed that after solidification, δ‐ferrite and NbC carbide particles were formed in the γ matrix while heat treatment eliminated the δ phase. Tensile test results showed that for the as‐prepared alloy yield strength varied between 336MPa and 352MPa, tensile strength between 559MPa and 589MPa, and elongation between 50 and 58%. However, heat treatment resulted in a 20‐22% decrease in yield strength, a 5‐10% decrease in tensile strength, and a 5% decline in elongation. The potentiodynamic (PD) polarization test results showed that the ICORR and the corrosion rate of the WAAM 347 stainless steel in the as‐prepared condition were separately 4.9 times and 5.6 times higher than the wrought alloy. After heat treatment, the ICORR increased from 5.84×10‐6 A/cm2 in the as‐prepared alloy to 6.68×10‐6 A/cm2, and the corrosion rate from 0.0678 to 0.0776 mm/y. This means that the heat treatment deteriorated the corrosion resistance of the WAAM 347 stainless steel alloy by about 14%.This article is protected by copyright. All rights reserved.

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Direct additive manufacturing of metal parts for automotive applications

Cited by 52 publications

References 16 publications

Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining

Dimensional Characterization and Hybrid Manufacturing of Copper Parts Obtained by Atomic Diffusion Additive Manufacturing, and CNC Machining

The semi-quantitative analysis of hole defects in metal additive manufacturing components using LIBS

Effects of Heat Treatment on Microstructure and Properties of 347 Stainless Steel Alloy Prepared by Wire Arc Additive Manufacturing

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