Integrated control of solidification microstructure and melt pool dimensions in electron beam wire feed additive manufacturing of Ti-6Al-4V

Gockel, Joy; Beuth, Jack; Taminger, Karen M. B.

doi:10.1016/j.addma.2014.09.004

Cited by 126 publications

(68 citation statements)

References 14 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…A number of projects sponsored by America Makes 28,29 are addressing the use/ reuse of powder as well as powder flow characteristics. The project involving Carnegie Mellon University (CMU), North Carolina State University (NCSU), and a large number of industry and government laboratory collaborators 29 is seeking to broaden the range of powders useable in laser and electron beam powder bed processes to allow machine users to balance constraints on cost and directly developing Process Mapping strategies [30][31][32][33][34][35] where beam power and velocity (i.e. P-V) are varied through a series of experiments (single bead on plate, single layer pads, multi-layer pads, components and component features).…”

Section: Process Control and Process Mappingmentioning

confidence: 99%

Overview of Materials Qualification Needs for Metal Additive Manufacturing

Seifi

Salem

Beuth

et al. 2016

JOM

Self Cite

500

183

View full text Add to dashboard Cite

This overview highlights some of the key aspects regarding materials qualification needs across the additive manufacturing (AM) spectrum. AM technology has experienced considerable publicity and growth in the past few years with many successful insertions for non-mission-critical applications. However, to meet the full potential that AM has to offer, especially for flightcritical components (e.g., rotating parts, fracture-critical parts, etc.), qualification and certification efforts are necessary. While development of qualification standards will address some of these needs, this overview outlines some of the other key areas that will need to be considered in the qualification path, including various process-, microstructure-, and fracture-modeling activities in addition to integrating these with lifing activities targeting specific components. Ongoing work in the Advanced Manufacturing and Mechanical Reliability Center at Case Western Reserve University is focusing on fracture and fatigue testing to rapidly assess critical mechanical properties of some titanium alloys before and after post-processing, in addition to conducting nondestructive testing/evaluation using micro-computerized tomography at General Electric. Process mapping studies are being conducted at Carnegie Mellon University while large area microstructure characterization and informatics (EBSD and BSE) analyses are being conducted at Materials Resources LLC to enable future integration of these efforts via an Integrated Computational Materials Engineering approach to AM. Possible future pathways for materials qualification are provided.

show abstract

Section: Process Control and Process Mappingmentioning

confidence: 99%

Overview of Materials Qualification Needs for Metal Additive Manufacturing

Seifi

Salem

Beuth

et al. 2016

JOM

Self Cite

500

183

View full text Add to dashboard Cite

show abstract

“…The results obtained were in agreement with published experimental observation. Gockel et al [83] have developed an FE model capable of simulating the material solidification of Ti64 in an electron beam wire feed AM process resulting in the prediction of the material microstructure and properties. A similar model of the LPD of titanium was developed by Crespo et al [66] in order to study the influence of the deposition path geometry on the melt pool stability as well as to estimate the adjustments of the deposition parameters, necessary to avoid hot spots.…”

Section: Laser Meltingmentioning

confidence: 99%

Additive manufacturing methods and modelling approaches: a critical review

Bikas

Stavropoulos

Chryssolouris

2015

Int J Adv Manuf Technol

1,170

443

View full text Add to dashboard Cite

Additive manufacturing is a technology rapidly expanding on a number of industrial sectors. It provides design freedom and environmental/ecological advantages. It transforms essentially design files to fully functional products. However, it is still hampered by low productivity, poor quality and uncertainty of final part mechanical properties. The root cause of undesired effects lies in the control aspects of the process. Optimization is difficult due to limited modelling approaches. Physical phenomena associated with additive manufacturing processes are complex, including melting/ solidification and vaporization, heat and mass transfer etc. The goal of the current study is to map available additive manufacturing methods based on their process mechanisms, review modelling approaches based on modelling methods and identify research gaps. Later sections of the study review implications for closed-loop control of the process.

show abstract

“…22 Also, continuous feed wire welding of materials such as titanium alloys has been used to build large components for aircraft structures and artistic sculptures. 23 These examples show how adaptation of robotic motion systems to the constraints of AM requires simultaneous development of compatible end effectors and software workflows, and an understanding of the system accuracy and its influence on part quality.…”

Section: Introductionmentioning

confidence: 99%

Conformal Robotic Stereolithography

Stevens

Oliver

Kirchmeyer

et al. 2016

3D Printing and Additive Manufacturing

View full text Add to dashboard Cite

Additive manufacturing by layerwise photopolymerization, commonly called stereolithography (SLA), is attractive due to its high resolution and diversity of materials chemistry. However, traditional SLA methods are restricted to planar substrates and planar layers that are perpendicular to a single-axis build direction. Here, we present a robotic system that is capable of maskless layerwise photopolymerization on curved surfaces, enabling production of large-area conformal patterns and the construction of conformal freeform objects. The system comprises an industrial six-axis robot and a custom-built maskless projector end effector. Use of the system involves creating a mesh representation of the freeform substrate, generation of a triangulated toolpath with curved layers that represents the target object to be printed, precision mounting of the substrate in the robot workspace, and robotic photopatterning of the target object by coordinated motion of the robot and substrate. We demonstrate printing of conformal photopatterns on spheres of various sizes, and construction of miniature three-dimensional objects on spheres without requiring support features. Improvement of the motion accuracy and development of freeform toolpaths would enable construction of polymer objects that surpass the size and support structure constraints imparted by traditional SLA systems.

show abstract

Integrated control of solidification microstructure and melt pool dimensions in electron beam wire feed additive manufacturing of Ti-6Al-4V

Cited by 126 publications

References 14 publications

Overview of Materials Qualification Needs for Metal Additive Manufacturing

Overview of Materials Qualification Needs for Metal Additive Manufacturing

Additive manufacturing methods and modelling approaches: a critical review

Conformal Robotic Stereolithography

Contact Info

Product

Resources

About