Stainless steel to titanium bimetallic structure using LENS™

Sahasrabudhe, Himanshu; Harrison, Ryan; Carpenter, Christian; Bandyopadhyay, Amit

doi:10.1016/j.addma.2014.10.002

Cited by 88 publications

(69 citation statements)

References 29 publications

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“…Owing to the temperature dependence and variable physical properties of the photopolymer, the control of the performance of the developed materials appears difficult. However, although multi-material AM is currently commercially available only in the case of a photopolymer, multi-material metal AM is under development [25,26]. If such AM is realized, the design process proposed in this paper could be used for materials that are more stiff and stable than photopolymer.…”

Section: Main Documentmentioning

confidence: 99%

Porous composite with negative thermal expansion obtained by photopolymer additive manufacturing

2015

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Additive manufacturing (AM) could be a novel method of fabricating composite and porous materials having various effective performances based on mechanisms of their internal geometries. Materials fabricated by AM could rapidly be used in industrial application since they could easily be embedded in the target part employing the same AM process used for the bulk material. Furthermore, multi-material AM has greater potential than usual single-material AM in producing materials with effective properties. Negative thermal expansion is a representative effective material property realized by designing a composite made of two materials with different coefficients of thermal expansion. In this study, we developed a porous composite having planar negative thermal expansion by employing multi-material photopolymer AM. After measurement of the physical properties of bulk photopolymers, the internal geometry was designed by topology optimization, which is the most effective structural optimization in terms of both minimizing thermal stress and maximizing stiffness. The designed structure was converted to a three-dimensional STL model, which is a native digital format of AM, and assembled as a test piece. The thermal expansions of the specimens were measured using a laser scanning dilatometer. The test pieces clearly showed negative thermal expansion around room temperature.

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Section: Main Documentmentioning

confidence: 99%

Porous composite with negative thermal expansion obtained by photopolymer additive manufacturing

2015

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“…The joints and interfaces typically have smaller heat-affected-zones than welded joints, and can be accomplished in a single manufacturing step, reducing the cost and time to design welded joints as well as perform multiple setups and joining processes. Various authors have investigated the use of this technique for joining common engineering materials such as Ti6Al4V to Stainless Steel using DED [35,106], Inconel 718 to Copper Alloy using DED [107], Ti6Al4V to CoCrMo [108], and Ti6Al4V to Copper using EBM [109] (see Figure 10 ). These materials and structures have applications in the aerospace, biomedical, nuclear, among other industries, where the use of multiple materials in small spaces poses a formidable challenge for welding or brazing.…”

Section: Emerging Metal-am Applications For Modeling and Simulationmentioning

confidence: 99%

“…Adapted from [109]. (B) Stainless Steel (SS410) to Ti6Al4V direct-bonding microstructure showing crack perpendicular to interface, fabricated via DED [35]. (C) Bimetallic structure composed of magnetic Stainless Steel (SS430) and non-magnetic stainless steel (SS316), fabrication via DED [36].…”

Section: Figurementioning

confidence: 99%

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

Bandyopadhyay

Traxel

2018

Additive Manufacturing

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128

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Next generation, additively-manufactured metallic parts will be designed with application-optimized geometry, composition, and functionality. Manufacturers and researchers have investigated various techniques for increasing the reliability of the metal-AM process to create these components, however, understanding and manipulating the complex phenomena that occurs within the printed component during processing remains a formidable challenge—limiting the use of these unique design capabilities. Among various approaches, thermomechanical modeling has emerged as a technique for increasing the reliability of metal-AM processes, however, most literature is specialized and challenging to interpret for users unfamiliar with numerical modeling techniques. This review article highlights fundamental modeling strategies, considerations, and results, as well as validation techniques using experimental data. A discussion of emerging research areas where simulation will enhance the metal-AM optimization process is presented, as well as a potential modeling workflow for process optimization. This review is envisioned to provide an essential framework on modeling techniques to supplement the experimental optimization process.

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“…Motivated by the increased application potential, and inspired from accessible published research in the more established associated fields of joining (e.g. welding) of dissimilar metals and manufacturing of functional graded materials, forays have already been made into additive manufacturing of multi-metal components by a few research groups [4] [5] [6] [7] [8]. However, additively manufactured multi-metal components are currently limited to research samples, primarily due to challenges in understanding, characterizing and controlling the involved manufacturing processes.…”

Section: Introductionmentioning

confidence: 99%

Laser additive manufacturing of multimaterial tool inserts: a simulation-based optimization study

Mohanty

Hattel

2017

SPIE Proceedings

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Selective laser melting is fast evolving into an industrially applicable manufacturing process. While components produced from high-value materials, such as Ti6Al4V and Inconel 718 alloys, are already being produced, the processing of multi-material components still remains to be achieved by using laser additive manufacturing. The physical handling of multi-material in a SLM setup continues to be a primary challenge along with the selection of process parameters/plan to achieve the desired results -both challenges requiring considerable experimental undertakings. Consequently, numerical process modelling has been adopted towards tackling the latter challenge in an effective manner.In this paper, a numerical simulation based optimization study is undertaken to enable selective laser melting of multi-material tool inserts. A standard copper specimen covered by a thin layer of nickel is chosen, over which a layer of steel has been deposited using cold-spraying technique, such as to protect the microstructure of Ni during selective laser melting. The process modelled thus entails additively manufacturing a steel tool insert around the multi-material specimen with a goal of achieving a dense product while preventing recrystallization in the Nickel layer. The process is simulated using a high-fidelity thermo-microstructural model with constant processing parameters to capture the effect on Nickel layer. Based on results, key structural and process parameters are identified, and subsequently an optimization study is conducted using evolutionary algorithms to determine the appropriate process parameter values as well as processing sequence. The optimized process plan is then used to manufacture real multi-material tool insert samples by selective laser melting.

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Stainless steel to titanium bimetallic structure using LENS™

Cited by 88 publications

References 29 publications

Porous composite with negative thermal expansion obtained by photopolymer additive manufacturing

Porous composite with negative thermal expansion obtained by photopolymer additive manufacturing

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

Laser additive manufacturing of multimaterial tool inserts: a simulation-based optimization study

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