System-level integration tools for laser-based powder bed fusion enabled process chains

Penchev, Pavel; Bhaduri, Debajyoti; Carter, Luke; Mehmeti, Aldi; Essa, Khamis; Dimov, Stefan Simeonov; Adkins, Nicholas J.E.; Maillol, Nathalie; Bajolet, Julien; Maurath, Johannes; Jurdeczka, Uwe

doi:10.1016/j.jmsy.2018.12.003

Cited by 17 publications

(14 citation statements)

References 30 publications

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“…The fixture includes a stationary base and two moving jaws with slots that hold the preforms firmly during the PBF operation. The stationary base is fixed to a pallet or a PBF build plate of the modular workpiece holding device via 2 M6 bolts [15] as shown in the exploded view in Figure 2(a), while M4 bolts are used to fix the moving jaws to the stationary base and thus to provide the necessary clamping force for holding the MIM preforms firmly Figure 2(b).In total, five custom fixtures were produced for batch manufacture of hybrid components. The slots were numbered to reference any hybrid components produced in a given PBF build.…”

Section: Test Part and Fixture Design For Batch Processingmentioning

confidence: 99%

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Mehmeti

Penchev

Lynch

et al. 2020

RPJ

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Purpose The paper reports an investigation into the mechanical behaviour of hybrid components produced by combining the capabilities of metal injection moulding (MIM) with the laser-based powder bed fusion (PBF) process to produce small series of hybrid components. The research investigates systematically the mechanical properties and the performance of the MIM/PBF interfaces in such hybrid components. Design/methodology/approach The MIM process is employed to fabricate relatively lower cost preforms in higher quantities, whereas the PBF technology is deployed to build on them sections that can be personalised, customised or functionalised to meet specific technical requirements. Findings The results are discussed, and conclusions are made about the mechanical performance of such hybrid components produced in batches and also about the production efficiency of the investigated hybrid manufacturing (HM) route. The obtained results show that the proposed HM route can produce hybrid MIM/PBF components with consistent mechanical properties and interface performance which comply with the American Society for Testing and Materials (ASTM) standards. Originality/value The manufacturing of hybrid components, especially by combining the capabilities of additive manufacturing processes with cost-effective complementary technologies, is designed to be exploited by industry because they can offer flexibility and cost advantages in producing small series of customisable products. The findings of this research will contribute to further develop the state of the art in regards to the manufacturing and optimisation of hybrid components.

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Section: Test Part and Fixture Design For Batch Processingmentioning

confidence: 99%

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Mehmeti

Penchev

Lynch

et al. 2020

RPJ

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“…These were held in modular devices, Fig. 1(a), that were developed and validated in a previous study for integrating laser-based powder bed fusion processes with other complementary pre-processing (machining or metal injection moulding) and post-processing technologies in hybrid manufacturing platforms [5]. They ensured a positional accuracy of the AM sections on the preforms between ~10-21 µm.…”

Section: Methodsmentioning

confidence: 99%

Evaluation of surface/interface quality, microstructure and mechanical properties of hybrid additive-subtractive aluminium parts

et al. 2019

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“…Another approach for creating hybrid AM solutions is the integration of AM technologies with pre-processing and postprocessing processes into multi-setup manufacturing platforms through the use of common work holding systems. The design and implementation of such modular work holding system were reported for integrating the LPBF process into AM enable process chains [122].…”

Section: Hybrid Additive/machining Solutionsmentioning

confidence: 99%

“…The modular work holding system reported in [122] was later employed by Badhuri et al [82] to investigate the surface integrity, microstructure and mechanical properties of hybrid AM aluminium parts produced by employing LPBF followed by some machining operations. In another research, the same work holding system was deployed to build LPBF structures on top of metal injection moulded (MIM) preforms and thus Fig.…”

Section: Hybrid Additive/machining Solutionsmentioning

confidence: 99%

Powder-based laser hybrid additive manufacturing of metals: a review

Jiménez

Bidare

Hassanin

et al. 2021

Int J Adv Manuf Technol

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Recent advances in additive manufacturing (AM) have attracted significant industrial interest. Initially, AM was mainly associated with the fabrication of prototypes, but the AM advances together with the broadening range of available materials, especially for producing metallic parts, have broaden the application areas and now the technology can be used for manufacturing functional parts, too. Especially, the AM technologies enable the creation of complex and topologically optimised geometries with internal cavities that were impossible to produce with traditional manufacturing processes. However, the tight geometrical tolerances along with the strict surface integrity requirements in aerospace, biomedical and automotive industries are not achievable in most cases with standalone AM technologies. Therefore, AM parts need extensive post-processing to ensure that their surface and dimensional requirements together with their respective mechanical properties are met. In this context, it is not surprising that the integration of AM with post-processing technologies into single and multi set-up processing solutions, commonly referred to as hybrid AM, has emerged as a very attractive proposition for industry while attracting a significant R&D interest. This paper reviews the current research and technology advances associated with the hybrid AM solutions. The special focus is on hybrid AM solutions that combine the capabilities of laser-based AM for processing powders with the necessary post-process technologies for producing metal parts with required accuracy, surface integrity and material properties. Commercially available hybrid AM systems that integrate laser-based AM with post-processing technologies are also reviewed together with their key application areas. Finally, the main challenges and open issues in broadening the industrial use of hybrid AM solutions are discussed.

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System-level integration tools for laser-based powder bed fusion enabled process chains

Cited by 17 publications

References 30 publications

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Mechanical behaviour and interface evaluation of hybrid MIM/PBF stainless steel components

Evaluation of surface/interface quality, microstructure and mechanical properties of hybrid additive-subtractive aluminium parts

Powder-based laser hybrid additive manufacturing of metals: a review

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