On the mechanical integrity of AA6082 3D structures deposited by hybrid metal extrusion &amp; bonding additive manufacturing

Blindheim, Jørgen; Grong, Ø.; Welo, Torgeir; Steinert, Martin

doi:10.1016/j.jmatprotec.2020.116684

Cited by 23 publications

(10 citation statements)

References 5 publications

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“…Simulations for model 1 have been carried out at two different rotational speeds of the extruder, 4 RPM and 50 RPM, where the former being the setting used for prior full-scale experiments [4]. Figure 8 shows the length of the extrusion grip zone for the initial condition (a) and for steady-state for the two rotational speeds considered in the study (b and c).…”

Section: Modelmentioning

confidence: 99%

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Investigating the Mechanics of Hybrid Metal Extrusion and Bonding Additive Manufacturing by FEA

Blindheim

Welo

Steinert

2019

Metals

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Hybrid Metal Extrusion & Bonding Additive Manufacturing (HYB-AM) is a hybrid manufacturing technology for the deposition of layered metal structures. This new deposition process is a complex metal forming operation, yet there is significant lack of knowledge regarding the governing mechanisms. In this work, we have used finite element analysis (FEA) to study material flow in the extruder, as well as the conditions at the interfaces of the deposited extrudate and the substrate, aiming to identify and characterize the process parameters involved. Analysis of the material flow shows that the extrusion pressure is virtually independent of the deposition rate. Furthermore, from the simulations of the material deposition sequence, it is clearly visible how the contact pressure at the interface will drop below the bonding threshold if the feed speed is too high relative to the material flow through the die. The reduced pressure also leads to the formation of a 'gas-pocket' inside the die, thus further degrading the conditions for bonding. The analyses of the process have provided valuable insights for the further development and industrialization of the process. the process on a proof-of-concept level and exploring the potential of the process [3]. More recently, a full-scale experiment was carried out to assess the mechanical integrity of a deposited structure [4]. Microscopy analyses show that fully dense bonding interfaces can be achieved, though some voids can be observed between the individual stringers. Observations of fracture surfaces reveal areas of full metallic bonding; however, regions of kissing-bonds and lack of bonding are also visible. Through these full-scale experiments, the HYB-AM process has demonstrated its proof-of-concept and capability for processing advanced aluminium alloys. Nevertheless, this process is a complex metal forming operation, and the governing mechanisms need to be better understood in order to optimize the process towards industrialization.

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Section: Modelmentioning

confidence: 99%

“…the process on a proof-of-concept level and exploring the potential of the process [3]. More recently, a full-scale experiment was carried out to assess the mechanical integrity of a deposited structure [4]. Microscopy analyses show that fully dense bonding interfaces can be achieved, though some voids can be observed between the individual stringers.…”

mentioning

confidence: 99%

Investigating the Mechanics of Hybrid Metal Extrusion and Bonding Additive Manufacturing by FEA

Blindheim

Welo

Steinert

2019

Metals

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“…In the last years, most of the interest of the additive manufacturing community has been devoted to the fabrication of hybrid structures [13][14][15] to meet the more demanding requirements of aerospace and automotive industries [16]. In this scenario, a lot of researchers of cold spray tried to produce metallic coatings on polymeric substrates to couple the lightweight of polymers with the wear resistance, physical properties and hardness of metals [17][18][19].…”

Section: Introductionmentioning

confidence: 99%

Cold spray deposition of metallic coatings on polymers: a review

et al. 2021

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Cold spray deposition, which can be framed in the wider family of additive manufacturing, is a manufacturing technique that is able to produce coatings on diverse types of substrates through the deposition of feedstock powder. As a low-temperature process, cold spray represents a potential solution for the metallization of temperature-sensitive materials, i.e. polymers and polymer matrix composites. The study of the cold spray technology for the metallization of polymers is still in its early stage, and the deposition mechanisms of metals on polymer-based materials are not thoroughly understood yet. On these premises, a review on this topic is needed to systematically depict the actual state of the art and to provide a reliable and well-organized overview discussing all the theories arisen in these years. In summary, this review aims: i) to collect all the available literature and enucleate the most discussed and interesting points (the most prevailing theories regarding the bonding mechanisms, the influence of the different process parameters and the main characteristics of cold-sprayed coating), providing a reliable and well-organized state of the art; ii) to define the open questions and to delineate the directions of future work.

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“…Extruded materials possess a combination of properties such as high strength and density, high ductility, good workability and weldability [6], high hardness, tensile and compressive strength [7], yield, and ultimate tensile strength [8]. Severe plastic deformation methods can produce ultrafine-grained material with high ductility and strength [9].…”

Section: Introductionmentioning

confidence: 99%

Effects of cold extrusion on the mechanical properties of scrapped copper coil

Olawore¹,

Oladosu²,

Sadiq³

et al. 2021

JES

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The recycling of copper coil into finished products via sand casting with subsequent cold extrusion was investigated. This paper examined the effects of cold extrusion on the mechanical properties of the scrapped copper coil using a locally manufactured extruder with a conventional face die. The mechanical properties tested on the extrudates are limited to hardness, tensile, and compressive strength. The results reveal that the hardness of extruded copper of 11.10 mm and 11.45 mm improved significantly by 39 % and 41 %, respectively, compared with respective non-extruded copper. The compressive and tensile strength increases by 42 % and 22 %, respectively, for 11.10 mm extruded copper compared with the corresponding non-extruded copper. Also, the elongation of the extruded copper of 11.10 mm and 11.45 mm increases by 33 % and 34 %, respectively. It was deduced that the extruded copper is more ductile than the non-extruded copper. The micrograph reveals that grains in non-extruded copper are relatively coarse and nonuniform with voids, but fine and relatively uniform grains are obtained in extruded copper. The grains are refined during cold extrusion, and voids and dislocations are reduced significantly.

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On the mechanical integrity of AA6082 3D structures deposited by hybrid metal extrusion & bonding additive manufacturing

Cited by 23 publications

References 5 publications

Investigating the Mechanics of Hybrid Metal Extrusion and Bonding Additive Manufacturing by FEA

Investigating the Mechanics of Hybrid Metal Extrusion and Bonding Additive Manufacturing by FEA

Cold spray deposition of metallic coatings on polymers: a review

Effects of cold extrusion on the mechanical properties of scrapped copper coil

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