Search Results for laser-based powder bed fusion

The manufacture of electric motors using additive methods offers potential advantages of increased efficiency, weight reduction, and customizability over traditional processes. This article describes some key developments and challenges related to additively manufactured electric motors in terms of manufacturing, materials development, and design.

A novel framework including experimental and model-based techniques saves time and enables the introduction of new alloys for additive manufacturing. This article describes the first phase of the probabilistic machine learning framework that was successfully demonstrated to rapidly define optimum parameter sets for commercial high-temperature nickel superalloys, as well as to guide alloy design and selection for compatibility with laser powder bed fusion additive manufacturing.

Although the widespread use of titanium alloys is constrained by high costs, powder metallurgy techniques such as additive manufacturing (AM) represent an economical approach to fabricating titanium components. Various approaches to AM, along with examples of components made by different AM processes, are presented. The microstructures and mechanical properties of Ti-6Al-4V produced by AM are also discussed and compared with cast and wrought products. Finally, the economic advantages of AM compared to conventional processing are presented.

Fabrication of aerospace components using additive manufacturing (AM) has matured to the point where part microstructures and mechanical properties compare well with those of conventionally produced material. This article discusses the basics of AM, part design considerations, CAD models, and build and powder removal considerations.

Laser powder bed fusion (LBFP) additive manufacturing is a potential route for the rapid qualification of new materials for use in nuclear reactor design. Process anomalies such as spatter particles can induce lack of fusion (LOF) voids that may adversely affect the material's mechanical performance. This examination of the spatter particle process in a nickel superalloy using X-ray computed tomography and optical microscopy was conducted to identify possible causes for the formation of LOF voids and other variations during LBPF processing.

In order to expand the choice of materials available for use in additive manufacturing, parameters that consider welding metallurgy, laser powder interaction, and post processing must be developed. This article describes the outcomes of process development for a steel and stainless steel alloy that are not standard materials for laser powder bed fusion equipment.

Enhanced mining tool performance is achieved through the use of reclaimed NiCrBSi-WC powders in laser metal deposition. Collection, analysis, and reuse of spilled powder lowers production costs and reduces environmental impact.

This entry won the prestigious Jacquet-Lucas Award for Best in Show in the 2020 International Metallographic Contest. In the research discussed in this article, light microscopy was applied to a Co28Cr6Mo alloy for a biomedical application processed by laser bed powder fusion (LPBF) additive manufacturing.

In Germany, the Federal Institute for Materials Research and Testing (BAM) is addressing challenges in the implementation of additive manufacturing on the industrial landscape for safety-critical applications. This article provides an overview of BAM’s activities in additive manufacturing with a focus on safety (both for applications and the environment) and AM technology innovation for a wide range of materials and manufacturing locations.

Metal 3D printing is expanding manufacturing possibilities by enabling new designs and improved outcomes. This article discusses some recent advances in processes and in metals suitable for additive manufacturing.

Metal additive manufacturing has steadily progressed over the past decade, with today’s directed energy deposition processes enabling rapid builds of large structures in near-net shape—and with minimal machining required to achieve final dimensions.

The fraction and size of pores present in EBM Ti-6Al-4V specimens varies depending on the melting strategy used, whether linear raster melting or point melting.

This article reviews additive manufacturing technologies that can be used for manufacturing ceramics and ceramic-based composites. Stereolithography and associated techniques offer the possibility of producing ceramic components with finer resolution. Powder-based techniques like binder jetting and indirect selective laser sintering can be used for designing porous ceramics. Selective laser melting offers practitioners the option of manufacturing ceramics with minimal post-processing requirements, although further research is needed to decrease its cost.

The high heating and cooling rates of additive manufacturing make it a good fit for metallic glasses, whose high elasticity, strength, hardness, and corrosion resistance are used in high-performance applications such as aerospace, defense, and biomedical devices.

4D printing enables fabrication of complex objects that transform over time (the fourth dimension) when subjected to external stimuli. 4D printing of metallic functional materials is of special interest due to their capacity for self-assembly and multifunctionality, with the added benefit of higher actuation capability, in comparison with polymeric materials.

Ahead of formal certification, many advanced metals have been qualified for 3D printing, allowing for the creation of previously impossible aerospace parts including for the hypersonic environment.

Fabrication of aerospace components using additive manufacturing (AM) has matured to the point where part microstructures and mechanical properties compare well with those of conventionally produced material. This article looks at characteristics of AM methods, post-processing of AM parts, and AM part properties.

The 15th World Conference on Titanium included papers on titanium alloy development, efforts to reduce Ti powder costs, additive manufacturing, and computational materials modeling tools. This article reviews some of the key advances reported at the conference.

Temperature measurement, unvented cavities, loose powder, and direct contact of certain metals must be considered during process development for vacuum heat treatment of additively manufactured parts.

This article provides a brief overview of the many ways that artificial intelligence and machine learning are being used for materials and manufacturing research. Several case studies show how the discovery, development, and deployment of novel materials are being dramatically accelerated through automation and data-driven models.