Metal hybrid additive manufacturing: state-of-the-art

Sefene, Eyob Messele; Hailu, Yeabsra Mekdim; Tsegaw, Assefa Asmare

doi:10.1007/s40964-022-00262-1

Cited by 38 publications

(8 citation statements)

References 54 publications

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“…The material selection which will be used for this setting were discussed on material section. The equation of quality code for "larger is better" is explained, Equation (4) [37].…”

Section: Taguchi Methods and Analysis Of Variance (Anova)mentioning

confidence: 99%

“…The material selection which will be used for this setting were discussed on material section. The equation of quality code for “larger is better” is explained, Equation (4) [37].

\vcenter{\openup.5em\halign{$\displaystyle{#}$\cr {S \over N}(\delta ) = 10log10{1 \over n}\textstyle{{\sum _{i = 1}^n}} {1 \over {y_{ijk}^2 }}\hfill\cr}}

…”

Section: Experimental Processingmentioning

confidence: 99%

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Study on lap joining and characterization of tin (Sn) powder on stainless steel SS304 using microwave heating

Tayier,

Janasekaran,

Tai

2023

Materialwissenschaft Werkst

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Metal bonding via joints of low melting point materials such as zinc and tin has been technically challenging. This paper presents a unique technique for bonding small dimensions and the low melting point of materials through the microwave hybrid heating (MHH) process. Joint of stainless steel SS304 was applied to the joint with the tin (Sn) powder with the application of microwave radiation by using domestic microwave oven at 2.45 GHz of constant frequency, 200–360 W of microwave power, 120–180 s of exposure time, and 10–20 % of the epoxy rate. A developed heat chamber was used as a susceptor and insulator in the microwave hybrid heating (MHH) process. The tin powder and parent metals were strongly bonded as lap position by the microwave hybrid heating (MHH) process at 360 W of microwave power, 180 s of constant exposure time, and 20 % of the constant epoxy rate. Characterization of the joint was evaluated through microhardness and x‐ray diffraction (XRD) analysis techniques. It was found that the intermetallic compounds (phase) of nickel tin (NiSn), iron tin (Fe1.84Sn), sulfur tin (SSn), chromium tin (Cr2Sn3), chromium tin (CrSn2), and tin phosphorus (SnP) at the joint surface with highest microhardness obtained at 498.4 HV 0.05 at 360 W of microwave power.

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“…The material selection which will be used for this setting were discussed on material section. The equation of quality code for "larger is better" is explained, Equation (4) [37].…”

Section: Taguchi Methods and Analysis Of Variance (Anova)mentioning

confidence: 99%

“…The material selection which will be used for this setting were discussed on material section. The equation of quality code for “larger is better” is explained, Equation (4) [37].

\vcenter{\openup.5em\halign{$\displaystyle{#}$\cr {S \over N}(\delta ) = 10log10{1 \over n}\textstyle{{\sum _{i = 1}^n}} {1 \over {y_{ijk}^2 }}\hfill\cr}}

…”

Section: Experimental Processingmentioning

confidence: 99%

Study on lap joining and characterization of tin (Sn) powder on stainless steel SS304 using microwave heating

Tayier,

Janasekaran,

Tai

2023

Materialwissenschaft Werkst

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“…In addition, lightweight elements, such as interior cavities or webs, may also be easily built. Figure 11 shows LUMEX-Avance 25-machined parts [76].…”

Section: Additive-subtractive Hybrid Manufacturingmentioning

confidence: 99%

Hybrid Laser Additive Manufacturing of Metals: A Review

Yue,

Zhang,

Zheng

et al. 2024

Coatings

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Due to the unparalleled benefits of traditional processing techniques, additive manufacturing technology has experienced rapid development and continues to expand its applications. However, as industrial standards advance, the pressing needs for high precision, high performance, and high efficiency in the manufacturing sector have emerged as critical bottlenecks hindering the technology’s progress. Single-laser additive manufacturing methods are insufficient to meet these demands. This review presents a comprehensive exploration of metal hybrid laser additive manufacturing technology, encompassing various aspects, such as multi-process hybrid laser additive manufacturing, additive–subtractive hybrid manufacturing, multi-energy hybrid additive manufacturing, and multi-material hybrid additive manufacturing. Through a thorough examination of the principles of laser additive manufacturing technology and the concept of hybrid manufacturing, this paper investigates in depth the notable advantages of hybrid laser additive manufacturing technology. It provides valuable insights and recommendations to guide the development and research of innovative machining technologies.

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“…Hybrid additive manufacturing evolves from a combination of additive and subtractive machining to benefit from the advantages of both technologies. 1 As additive manufacturing excels by new fabrication possibilities, arising of the high freedom of design and the various usable materials, 2 conventional manufacturing technologies provide high-precision components and proper surface quality. 3 Due to a combination of both technologies, the disadvantages of the additive manufacturing, namely, surface roughness and fitting accuracy, can be excluded, exploiting the conventional fabrication techniques like, e.g., milling or turning.…”

Section: Introductionmentioning

confidence: 99%

Additive manufacturing of Nickel-based superalloy: optimization of surface roughness using integrated high-speed milling

Sommer,

Safi,

Esen

et al. 2024

Laser 3D Manufacturing XI

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Hybrid additive manufacturing techniques capitalise the advantages of additive manufacturing, while, at the same time, circumvent its disadvantages by using in-situ combined subtractive processes. A particularly promising hybrid additive manufacturing approach unites Laser Powder Bed Fusion (LPBF) with in-situ high-speed milling.Here, the advantages of LPBF such as, e.g., design of freedom and choice of a variety of qualified metal powders can be used, shaping complex as well as custom-designed 3D metal parts. The in-situ high-speed milling process, in turn, yields finished surfaces with superior surface roughness and guarantees high geometrical accuracy without the need of any further post processing. While the typical process sequence of this hybrid approach interrupts the LPBF process every 3-10 layers by milling the accessible surface regions of interest, different challenges arise, as this milling process is directly integrated into the powder bed of the LPBF chamber. Wear characteristics of the milling tools increase as a consequence of the surrounding powder, getting reinforced by the elevated temperatures of the thus far printed parts. As being a super-alloy, Inconel 718 is a promising and well-studied candidate for LPBF additive manufacturing, exhibiting high strength and good mechanical properties. However, it is also well known to be a difficult to machine material. This contribution evaluates the process parameters of this innovative hybrid combination with particular focus on optimizing the surface quality. By varying the high-speed milling process parameters infeed, z-pitch, feed rate and rotational velocity of the milling cutter, smooth surfaces with a roughness of R a < 1µm are accomplished. In addition, the wear characteristics of the milling cutter are investigated, characterizing the flank wear as well as the abrasion of the cutters coating. As the flank wear gets increased by the surrounding powder during the milling process, a specific milling path suction is installed, extracting the powder at the surfaces of the components ahead of the milling path. Advantages of this approach are quantified in a comparative study by the analysis of the milling cutters lifetime.

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Metal hybrid additive manufacturing: state-of-the-art

Cited by 38 publications

References 54 publications

Study on lap joining and characterization of tin (Sn) powder on stainless steel SS304 using microwave heating

Study on lap joining and characterization of tin (Sn) powder on stainless steel SS304 using microwave heating

Hybrid Laser Additive Manufacturing of Metals: A Review

Additive manufacturing of Nickel-based superalloy: optimization of surface roughness using integrated high-speed milling

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