Forming properties of additively manufactured monolithic Hastelloy X sheets

Rosenthal, Stephan; Platt, Sebastian; Hölker-Jäger, Ramona; Gies, S.; Kleszczynski, Stefan; Tekkaya, A. Erman; Witt, Gerd

doi:10.1016/j.msea.2019.03.035

Cited by 30 publications

(6 citation statements)

References 23 publications

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“…Moreover, the second group can be further subdivided into three subgroups, depending on the morphology, and expected use of the additively manufactured sheets (refer also to Table 1): Fabrication of customised preforms with selective features by MAM – used for hybrid manufacturing solutions comprising metal deposition, cutting and sheet forming in a single clamping, 19 Customisation of tailored blanks with local reinforcements – used to increase the stiffness of commercial wrought sheets and to prevent excessive thinning during forming, 13 Fabrication of sandwich sheets with specially designed core structures and optimised properties – used to minimise weight without compromising the formability of the sheets. 20 …”

Section: Introductionmentioning

confidence: 99%

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Formability of wire-arc deposited AISI 316L sheets for hybrid additive manufacturing applications

Pragana

Bragança

Reis

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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This paper is focused on the formability of wire-arc additively manufactured AISI 316L stainless steel sheets with the purpose of analysing the feasibility of including this material in hybrid additive manufacturing chains involving sheet metal forming operations. Conventional tensile tests performed in specimens obtained from different orientations to the building direction were carried out to characterise the mechanical properties, the strain loading paths and the limiting strains at fracture. Microstructure observations combined with fractography analysis add insight to the results by establishing a link between the forming limits by fracture and the crack opening mechanisms. Results obtained for wrought commercial AISI 316L stainless steel sheets are included for comparison purposes and reveal that the additively manufactured sheets have a much stronger anisotropic behaviour and poorer formability due to their dendritic-based microstructure. Still, the forming limits obtained from the experiments allow concluding that the additively manufactured sheets can withstand large plastic deformations and, therefore, can be used in hybrid additive manufacturing routes.

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Section: Introductionmentioning

confidence: 99%

“…Fabrication of sandwich sheets with specially designed core structures and optimised properties – used to minimise weight without compromising the formability of the sheets. 20…”

Section: Introductionmentioning

confidence: 99%

Formability of wire-arc deposited AISI 316L sheets for hybrid additive manufacturing applications

Pragana

Bragança

Reis

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…A further combination of additive manufacturing and forming are components manufactured by AM and formed subsequently. Rosenthal et al [16] investigated the additive manufacturing of semi-finished products, which are formed in a final step, and compared this process chain with singular additive manufacturing of the final part geometry. In this case, the build time in AM is reduced by approximately 50% for this geometry.…”

Section: State Of the Artmentioning

confidence: 99%

Alternating Additive Manufacturing and Forming—An Innovative Manufacturing Approach

Papke

Hafenecker

Römisch

et al. 2023

JMMP

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In this work, an innovative manufacturing approach that includes a fully linked and integrated manufacturing system consisting of a laser-based directed energy deposition (DED-LB/M) module and a forming press is presented. The alternating additive manufacturing (AM) process is based on a combination of a DED-LB/M process using a laser power of 600 W and a feed rate of 400 mm/min and a subsequent forming process, in which the structure is upset with a hydraulic press using a constant forming force of 500 kN in order to smooth the surface and influence the accuracy of the components. For the generation of a fundamental process understanding, a cuboid, basic shape was chosen as geometry for the investigations. The aim is to improve part properties by applying the process steps to generate part properties, which are superior to solely additive manufactured material. It is shown that the geometry of additive manufactured structures can be adapted, and the top surface can be smoothed due to the forming operation. The mean roughness value Rz decreases up to 50% after the forming operation. The hardness can be increased by work hardening. Of special interest is that the higher hardness can be kept up even though a further DED-LB/M process step and forming operation are applied to the additively manufactured and formed structure again. Finally, an analysis of the new manufacturing approach regarding its potential is given.

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“…However, what this paper aims to explore is not the hybridization of additive manufacturing by integration of metal cutting operations but the hybridization of additive manufacturing by integration of metal forming operations to increase its overall sustainability and to reduce its dependence on the batch size [15,16]. Several feasibility studies have been recently published on the integration of sheet metal forming [17][18][19][20] and bulk metal forming [21][22][23][24] with additive manufacturing. The state-of-the-art review by Pragana et al [25] presents and discusses the major scientific and technological breakthroughs resulting from these studies but also allows concluding that hybridization of additive manufacturing by integration of tube forming operations is an open field of research.…”

Section: Introductionmentioning

confidence: 99%

Integration of tube end forming in wire arc additive manufacturing: An experimental and numerical investigation

Pragana

Bragança

Martins

2021

Int J Adv Manuf Technol

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Integration of tube end forming operations in metal additive manufacturing routes has a great potential for the fabrication of customized features in additively deposited hollow parts. This paper is focused on the integration of tube expansion with rigid tapered conical mandrels to highlight the advantages in the construction of overhanging flares derived from the elimination of support structures and prevention of humping. The work draws from the mechanical and formability characterization of stainless steel AISI 316L tubes produced by wire arc additive manufacturing (WAAM) to the experimental and numerical simulation of the construction of overhanging flares by tube expansion. Strain loading paths obtained from digital image correlation and finite element analysis combined with the strain values at the onset of necking and fracture allow determining the critical ductile damage that additively deposited tubes can safely withstand. Results show that despite formability of additively deposited tubes being influenced by a dendritic based microstructure, their performance is adequate for tube end forming operations, such as tube expansion, to be successfully integrated in metal additive manufacturing without the need of using expensive hardware and complex deposition strategies.

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Forming properties of additively manufactured monolithic Hastelloy X sheets

Cited by 30 publications

References 23 publications

Formability of wire-arc deposited AISI 316L sheets for hybrid additive manufacturing applications

Formability of wire-arc deposited AISI 316L sheets for hybrid additive manufacturing applications

Alternating Additive Manufacturing and Forming—An Innovative Manufacturing Approach

Integration of tube end forming in wire arc additive manufacturing: An experimental and numerical investigation

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