Surface finishing by laser re-melting applied to robotized laser metal deposition

Bruzzo, Francesco; Catalano, Guendalina; Demir, Ali Gökhan; Previtali, Barbara

doi:10.1016/j.optlaseng.2020.106391

Cited by 22 publications

(7 citation statements)

References 35 publications

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“…The organic forms, undercuts, internal channels achievable via PBF processes require non-conventional finishing operations such as abrasive flow jet or electrochemical machining increasing the final cost of the product (Anilli, Demir, and Previtali 2018). The DED produced parts are characterized by irregular surfaces with high surface roughness (Bruzzo et al 2021). Combined with the large size their finishing operation may be best fit to be carried out during the deposition phase in a hybrid manufacturing scheme.…”

Section: Introductionmentioning

confidence: 99%

Role of metal 3D printing to increase quality and resource-efficiency in the construction sector

Kanyilmaz

Demir

Chierici

et al. 2022

Additive Manufacturing

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Section: Introductionmentioning

confidence: 99%

Role of metal 3D printing to increase quality and resource-efficiency in the construction sector

Kanyilmaz

Demir

Chierici

et al. 2022

Additive Manufacturing

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“…A robotic arm equipped with a DED powder system, named AddiTube [Figure 15(b) and 15(c)], was developed, consisting of 6-DOF ABB IRB 4600-45 manipulator, a 2-DOF building platform (ABB IRBP A-250) and a laser source with 3 kW maximum power output from IPG (YLS-3000). The objective is to show the possibility to improve the surface quality of AISI 316L thin-wall structures through laser re-melting, using the same laser equipment, after the deposition process (Bruzzo et al , 2021). Robotic arm laser-wire DED process is also being studied by researchers at Southern Methodist University, USA.…”

Section: Robotics-driven Additive Manufacturing Processesmentioning

confidence: 99%

“…(a) Robotic WAAM system (Evjemo et al , 2019); (b and c) robotic DED powder system (Bruzzo et al , 2021); (d) MX3D Bridge in printing stage (MX3D, 2021); and (e) at Dutch Design Week 2018…”

Section: Figurementioning

confidence: 99%

The role of robotics in additive manufacturing: review of the AM processes and introduction of an intelligent system

Pires

Azar

Nogueira

et al. 2021

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Purpose Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology. Design/methodology/approach AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices. Findings The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically. Research limitations/implications This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors. Originality/value The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.

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“…Despite these several advantages, the LMD process is still not widely applied on an industrial scale. Some of the key issues limiting its industrial application are the limited geometrical stability and the requirement of post-processing [6]. In LMD the deposited track dimensions vary as a function of the process parameters, but can also depend on the deposition trajectory and part geometry.…”

Section: Introductionmentioning

confidence: 99%

Interplay between powder catchment efficiency and layer height in self-stabilized laser metal deposition

Donadello

Furlan

Demir

et al. 2022

Optics and Lasers in Engineering

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Surface finishing by laser re-melting applied to robotized laser metal deposition

Cited by 22 publications

References 35 publications

Role of metal 3D printing to increase quality and resource-efficiency in the construction sector

Role of metal 3D printing to increase quality and resource-efficiency in the construction sector

The role of robotics in additive manufacturing: review of the AM processes and introduction of an intelligent system

Interplay between powder catchment efficiency and layer height in self-stabilized laser metal deposition

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