Sofiane GUESSASMA
[email protected]
Metal additive manufacturing MAM Current state of the art & challenges
Layout Processing routes Type of materials Applications Physical phenomena Characteristics of MAM parts Microstructure, surface state, mechanical performance
Challenges & opportunities
Processing routes Categories According to feed material PBF:Powder bed Fusion powder-based
wire-based
DED:Directed energy deposition
According to energy source
laser-based electron beam-based welding-based
Processing routes Categories PBF: Powder bed Fusion SLS: Selective laser Sintering SLM: Selective laser Melting EBM: Electron Beam Melting
DED: Directed energy deposition DMD: Directed Metal deposition MDD: Molten droplet deposition MWD: Metal Wire deposition GMAWD: Gas Metal Arc Welding deposition FDMD: Fused-coating based metal
Processing routes Charbi et al 2013
Direct metal deposition
Typical conditions
material: Ti6Al4V
Powder size 45 -75 µm, Laser 320 -500W, 0.4 mm, feed rate 1 – 3 g/min, speed 0.1 -0.6 m/min.
Processing routes Direct selective laser melting/Sintering Simchi et al. 2004
Abe et al 2001
TiA6V4
Haan et al 2015
iron Typical conditions
Simchi et al. 2004
Laser 6kW, 1070nm, 0.7 mm, Sheet 2mm, deposition 7°, rate 3 m/min, Ar shield 18l/min, droplets 500µm
Processing routes Molten droplet based AM Droplet speed 2 m/s
Samarji et al. 2017
Laser cladding detoured
Typical conditions Laser 6kW, 1070nm, 0.7 mm, Sheet 2mm, deposition 7°, rate 3 m/min, Ar shield 18l/min, droplets 500µm
Processing routes Laser metal-wire additive manufacturing
Ding et al. 2017
Typical conditions Laser source 1080 nm, 0.8 mm 200W Wire 0.4 mm Rate 15 -25 mm/s Laser/wire 45° Vaccum Materials Ti, Al alloys
Processing routes Gas metal arc welding AM Typical conditions
Yang et al. 2017
Process rendering: High energy efficiency Large deposition rate Cooling rates 30 °C/s
Shield gas Ar/CO2 15 l/min. Arc voltage 24V Current 180A Wire 1.2 mm Rate 5 mm/s Materials: Steel
Processing routes Fused-coating based metal
Fang et al. 2017
Typical conditions 700 W band heater Nozzle Tip 0.4 mm, Nozzle – substrate 0.8 – 2 mm Crucible pressure 150kPa Materials Rate 0.4 – 1.0 g/s SnPb alloy (melting 183°C) Speed 6 – 20 mm/s
Processing routes Process efficiency = densification
Effect of laser power
Effect of scan rate
DMLS Simchi et al. 2004
Types of materials Nickel alloys: Inconel625 Aluminum alloys: AlSi10Mg: Stainless steel: 316L Titanium alloys: Ti6Al4V Copper alloys Refractory materials: cobalt chrome, alumina
Applications Aerospace : Liquid-fueled rocket engines Inconel 625, jet engine parts 316L, airframe structural components Ti6Al4V, aircraft skin Ti6Al4V, missile and spacecraft parts Ti6Al4V
Marine applications
Automotive : exhaust manifolds (316L ) Bioengineering: Ti6Al4V, implant Co-based (CoCr) Energy industry: gas turbine engines
Characteristics of MAM parts Microstructure Discontinuous scan track
DMLS – Iron
DMLS – 316L Gu 2009
Necking is the result of rapid liquid melting (short heating cycle
