Dissimilar metals deposition by directed energy based on powder-fed laser additive manufacturing

Khodabakhshi, F.; Farshidianfar, M.H.; Bakhshivash, S.; Gerlich, A.P.; Khajepour, Amir

doi:10.1016/j.jmapro.2019.05.018

Cited by 69 publications

(18 citation statements)

References 30 publications

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“…Obtaining permanent joints from dissimilar metals is an urgent challenge, not only in the field of laser welding of dissimilar metals but also in such promising and science-intensive manufacturing areas as additive technologies (Direct Metal Deposition, (DMD), Selective Laser Melting (SLM)) [ 95 , 96 , 97 , 98 ] and technology of recovery cladding [ 99 , 100 ]. They also have problems with cracking, poor wettability, and flowability of the molten metal.…”

Section: Discussionmentioning

confidence: 99%

A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

Kuryntsev

2021

Materials

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Modern structural engineering is impossible without the use of materials and structures with high strength and low specific weight. This work carries out a quantitative and qualitative analysis of articles for 2016–2021 on the topic of welding of dissimilar alloys. It is found that laser welding is most widely used for such metal pairs as Al/Fe, Al/Ti, and Al/Cu. The paper analyzes the influence of the basic techniques, methods, and means of laser welding of Al/Fe, Al/Ti, and Al/Cu on the mechanical properties and thickness of the intermetallic compound (IMC). When welding the lap joint or spike T-joint configuration of Al/Fe, it is preferable to melt the steel, which will be heated or melted, by the laser beam, and through thermal conduction, it will heat the aluminum. When welding the butt-welded joint of Al/Fe, the most preferable is to melt the aluminum by the laser beam (150–160 MPa). When welding the butt-welded joint of Al/Ti, it is possible to obtain the minimum IMC and maximum mechanical properties by offsetting the laser beam to aluminum. Whereas when the laser beam is offset to a titanium alloy, the mechanical properties are 40–50% lower than when the laser beam is offset to an aluminum alloy. When lap welding the Al/Cu joint, under the impact of the laser beam on the aluminum, using defocusing or wobbling (oscillation) of a laser beam, it is possible to increase the contact area of electrical conductivity with the tensile shear strength of 95–128 MPa.

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Section: Discussionmentioning

confidence: 99%

A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

Kuryntsev

2021

Materials

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“…In solid-state AM processes, the temperature involved is lower than the melting point of the materials to be joined, preventing the defects occurring in fusion-based AM processes. In addition, the main challenge in production of dissimilar material structures relates to the formation of different brittle intermetallic compounds at the interface as a result of different coefficients of thermal expansion and different crystallographic structures [ 52 ]. When lower temperatures are involved in the AM process, dissimilar material structures can be fabricated without generating harmful intermetallic compounds [ 53 ].…”

Section: Additive Manufacturingmentioning

confidence: 99%

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

et al. 2021

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High requirements imposed by the competitive industrial environment determine the development directions of applied manufacturing methods. 3D printing technology, also known as additive manufacturing (AM), currently being one of the most dynamically developing production methods, is increasingly used in many different areas of industry. Nowadays, apart from the possibility of making prototypes of future products, AM is also used to produce fully functional machine parts, which is known as Rapid Manufacturing and also Rapid Tooling. Rapid Manufacturing refers to the ability of the software automation to rapidly accelerate the manufacturing process, while Rapid Tooling means that a tool is involved in order to accelerate the process. Abrasive processes are widely used in many industries, especially for machining hard and brittle materials such as advanced ceramics. This paper presents a review on advances and trends in contemporary abrasive machining related to the application of innovative 3D printed abrasive tools. Examples of abrasive tools made with the use of currently leading AM methods and their impact on the obtained machining results were indicated. The analyzed research works indicate the great potential and usefulness of the new constructions of the abrasive tools made by incremental technologies. Furthermore, the potential and limitations of currently used 3D printed abrasive tools, as well as the directions of their further development are indicated.

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“…This technology is equipped with an ability to create complex 3D parts without the use of tooling, which can reduce up to 50% of the product lead time. Due to the strange feature of AM techniques such as time efficient, cost-effective and can print wide range of materials such as ceramics [4][5][6], metals [7][8][9], food [10][11][12] and thermoplastics [13][14][15]; the AM process attracted a great deal of attention in the areas of automotive [16], aeronautical [17], medical [18], robotics [19], electronics [20], construction [21] and consumer goods manufacturing [22]. Recently, the additive manufacturing of solid propellant has gained interest due to the ability to form complex and intricate shapes.…”

Section: Introductionmentioning

confidence: 99%

Preliminary investigations on extrusion of high viscosity slurry using direct writing technique

Ali

Esakki

Praveen

et al. 2020

Int. J. Simul. Multidisci. Des. Optim.

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Traditionally solid propellants are manufactured using casting and molding techniques. The effective burning rate of solid propellants is strongly depended on its cross section and geometry. The preparation of mold and mandrel for the manufacturability of various geometric profiles are tedious, time consuming, increases the cost and more human efforts are needed. In order to mitigate these issues, a disruptive technology called additive manufacturing (AM) is in the verge of development. Although the method is effective, additional study must be conducted to improve the flow characteristics of slurries for the high solid loading and there is a huge necessity to reduce the prolonged curing time. The present study focuses on preliminary investigations of extrusion of high viscosity slurry using a pneumatically driven extrusion system. The slurry was prepared with a 80 wt.% solid loading of NaCl having particle sizes of 45 µm and 150 µm, 15.6 wt.% HTPB, 2.2 wt.% TDI, 2.2 wt.% DOA and 0.03 wt.% of ferric acrylacetonate. The slurry was extruded with an aid of pneumatically controlled extruder and each layer was formed. Formed by extruding the slurry using 1.65 mm internal diameter nozzle. Infrared (IR) heater was utilized to transfer the radiational energy for partial curing of each layer and thereby adhesion of other layer was guaranteed. Simulation is performed to determine the temperature distribution using ANSYS platform for comparing the curing temperature of the printed part top surface. Preliminary experiments confirm that extrusion of slurry and heating of each layer can be effectively achieved with the proposed 3D printing technique. Three tensile specimens were produced in accordance with ASTMD 412-C and their corresponding mechanical properties are evaluated. The printed parts have the tensile strength of 0.7 MPa, elongation of 4.85 % and modulus of elasticity of 18.5 MPa which are comparable with the properties of conventional casted part.

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Dissimilar metals deposition by directed energy based on powder-fed laser additive manufacturing

Cited by 69 publications

References 30 publications

A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

A Review: Laser Welding of Dissimilar Materials (Al/Fe, Al/Ti, Al/Cu)—Methods and Techniques, Microstructure and Properties

Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review

Preliminary investigations on extrusion of high viscosity slurry using direct writing technique

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