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Additive Manufacturing of Metal Components
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Additive Manufacturing of Metal Components

A topical collection in Applied Sciences (ISSN 2076-3417). This collection belongs to the section "Mechanical Engineering".

Viewed by 9289

Editors

Dr. Lonnie J. Love

E-Mail Website
Collection Editor
Manufacturing Systems Research Group, Oak Ridge National Laboratory, 2350 Cherahala Blvd, Knoxville TN, USA
Interests: design; robotics; hydraulics; additive manufacturing; nanomaterials
Special Issues, Collections and Topics in MDPI journals
Dr. Ryan R. Dehoff

E-Mail Website
Collection Editor
Manufacturing Systems Research Group, Oak Ridge National Laboratory, 2350 Cherahala Blvd, Knoxville, TN, USA
Interests: electron beam melting; laser metal deposition; ultrasonic additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Topical Collection Information

Dear Colleagues,

Metal additive manufacturing enables the rapid, low-volume production of highly complex metallic components. Numerous industries are highly interested in directly manufacturing metallic components, but there remains great uncertainty in terms of the processes and controls slowing widespread industrialization. This is complicated due to the tremendous flexibility in materials and processes, with each having their own strengths and weaknesses. Approaches vary from direct energy deposition to powder bed fusion, extrusion, and thermal and cold spray, to name just a few. Each of these processes, while simple in principle, exhibits its own complexity in terms of material properties that are a function of processing parameters, toolpaths, and systems and controls. In many cases, there seems to be more art than science when it comes to reliably being able to manufacture components using these advanced manufacturing processes. This uncertainty can lead to the slow adoption of the technologies in industrial settings.

We invite authors to contribute original research articles, as well as review articles, that will contribute to the area of metal additive manufacturing materials, processes, and controls.

Potential topics include but are not limited to the following:

  • Advanced materials for additive manufacturing;
  • Advanced metrology and control technology for metal additive manufacturing;
  • Data analytics and AI approaches to partial certification and control;
  • New metal additive manufacturing processes.

Dr. Lonnie J. Love
Dr. Ryan R. Dehoff
Collection Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • metal additive manufacturing
  • metrology
  • data analytics
  • machine learning

Published Papers (5 papers)

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2024

Jump to: 2023, 2022, 2021

16 pages, 15016 KiB  
Article
Deformation and Energy Absorption Performance of Functionally Graded TPMS Structures Fabricated by Selective Laser Melting
by Jian Song, Mengkang Wang, Dongming Li and Jun Zhang
Appl. Sci. 2024, 14(5), 2064; https://doi.org/10.3390/app14052064 - 01 Mar 2024
Viewed by 572
Abstract
Triply periodic minimal surface (TPMS) structures have unique geometries and excellent mechanical properties, which have attracted much attention in many fields. However, the relationship between different filling forms and different directions of functionally graded TPMS structures on energy absorption has not been fully [...] Read more.
Triply periodic minimal surface (TPMS) structures have unique geometries and excellent mechanical properties, which have attracted much attention in many fields. However, the relationship between different filling forms and different directions of functionally graded TPMS structures on energy absorption has not been fully studied. In this study, a functionally graded strategy was proposed to investigate the effect of filling form and direction gradient on the energy absorption of TPMS structures. The design of functionally graded Gyroid and Diamond TPMS cellular structures with multiple forms was characterized, and the structures were fabricated using additive manufacturing technology. The effects of uniformity and different directional gradients on the deformation and energy absorption properties of the structures were studied experimentally and numerically. According to the compression test results, it was found that different filling forms of the TPMS structure behave differently in terms of yield plateau and deformation pattern, and the sheet structures can develop a better deformation pattern to enhance energy absorption capacity. Functionally graded sheet Diamond TPMS cellular structures along the compression direction exhibit a 32% reduction in initial peak force, providing more advantages in structural deformation and energy absorption. More closely, it is possible to further reduce the initial peak force, delay the densification point, and thus increase the energy absorption capacity by designing functionally graded sheet Diamond TPMS based cellular structures. The results of this study provide valuable guidance for the design of high-performance impact-protection components. Full article
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2023

Jump to: 2024, 2022, 2021

16 pages, 2959 KiB  
Article
Ratcheting Simulation of Additively Manufactured Aluminum 4043 Samples through Finite Element Analysis
by M. Servatan, S. M. Hashemi and A. Varvani-Farahani
Appl. Sci. 2023, 13(20), 11553; https://doi.org/10.3390/app132011553 - 22 Oct 2023
Viewed by 861
Abstract
This study presents a finite element-based ratcheting assessment of additively manufactured aluminum 4043 samples undergoing asymmetric loading cycles. The Chaboche material model in ANSYS was utilized and the effects of mesh and element type were examined. Different element numbers were used in a [...] Read more.
This study presents a finite element-based ratcheting assessment of additively manufactured aluminum 4043 samples undergoing asymmetric loading cycles. The Chaboche material model in ANSYS was utilized and the effects of mesh and element type were examined. Different element numbers were used in a thorough convergence study to obtain independent meshing structures. The coefficients of this model were defined through stress–strain hysteresis loops determined from the strain-controlled tests. The backstress evolution and the corresponding yield surface translation in the deviatoric stress space were discussed as three different mesh elements of linear brick, quadratic tetrahedron, and quadratic brick were adopted. The magnitude of backstress was affected as different element types were employed. The first-order brick elements resulted in the highest backstress increments, while the lowest backstresses were determined when quadratic brick elements were taken. Backstress increments are positioned in an intermediate level with the use of quadratic tetrahedron elements. The choice of the element type, shape, and number influenced material ratcheting response over the loading process. The use of quadratic brick elements elevated the simulated ratcheting curves. The quadratic tetrahedron and linear brick elements, however, suppressed ratcheting level as compared with those of experimental data. The closeness of the simulated ratcheting results to those of the measured values was found to be highly dependent on these finite element variables. Full article
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24 pages, 10334 KiB  
Article
Additive Manufacturing for Lightweighting Satellite Platform
by Alberto Boschetto, Luana Bottini, Luciano Macera and Somayeh Vatanparast
Appl. Sci. 2023, 13(5), 2809; https://doi.org/10.3390/app13052809 - 22 Feb 2023
Cited by 7 | Viewed by 2512
Abstract
Lightweight structures with an internal lattice infill and a closed shell have received a lot of attention in the last 20 years for satellites, due to their improved stiffness, buckling strength, multifunctional design, and energy absorption. The geometrical freedom typical of Additive Manufacturing [...] Read more.
Lightweight structures with an internal lattice infill and a closed shell have received a lot of attention in the last 20 years for satellites, due to their improved stiffness, buckling strength, multifunctional design, and energy absorption. The geometrical freedom typical of Additive Manufacturing allows lighter, stiffer, and more effective structures to be designed for aerospace applications. The Laser Powder Bed Fusion technology, in particular, enables the fabrication of metal parts with complex geometries, altering the way the mechanical components are designed and manufactured. This study proposed a method to re-design the original satellite structures consisting of walls and ribs with an enclosed lattice design. The proposed new structures must comply with restricted requirements in terms of mechanical properties, dimensional accuracy, and weight. The most challenging is the first frequency request which the original satellite design, based on traditional fabrication, does not satisfy. To overcome this problem a particular framework was developed for locally thickening the critical zones of the lattice. The use of the new design permitted complying with the dynamic behavior and to obtain a weight saving maintaining the mechanical properties. The Additive Manufacturing fabrication of this primary structure demonstrated the feasibility of this new technology to satisfy challenging requests in the aerospace field. Full article
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2022

Jump to: 2024, 2023, 2021

14 pages, 25712 KiB  
Article
Tensile Properties of As-Built 18Ni300 Maraging Steel Produced by DED
by Jorge Gil, Ricardo Seca, Rui Amaral, Omid Emadinia, Abílio De Jesus and Ana Reis
Appl. Sci. 2022, 12(21), 10829; https://doi.org/10.3390/app122110829 - 25 Oct 2022
Cited by 2 | Viewed by 1660
Abstract
The mechanical behaviour of as-built DED-produced 18Ni300 Maraging steel was studied by manufacturing a wall-like structure from which three different specimen types were obtained: specimens in which the loading direction was the same as the printing direction (vertical), specimens in which these two [...] Read more.
The mechanical behaviour of as-built DED-produced 18Ni300 Maraging steel was studied by manufacturing a wall-like structure from which three different specimen types were obtained: specimens in which the loading direction was the same as the printing direction (vertical), specimens in which these two directions were perpendicular (horizontal), and bimetallic specimens in which the interface between the AISI 1045 substrate and the 18Ni300 steel was tested. The yield strength of the produced samples was 987.9±34.2, 925.9±89.7 and 486.7±47.2 MPa for the vertical, horizontal and bimetallic specimens, respectively, while the elongation to failure was 9.4±1.9, 18.3±2.3 and 14.06±0.6% in the same order. The latter specimen failed within the substrate-comprised portion of the specimen. Additionally, the fracture surfaces were analysed through scanning electron microscopy, concluding that while both surfaces consist of dimples, the horizontal specimen presented microporosities with a reduced diameter. A microhardness analysis in the printed wall-like structure following the printing direction yielded an average hardness of 392±21 HV0.3, with fluctuations along the build direction mostly within one standard deviation. Full article
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2021

Jump to: 2024, 2023, 2022

12 pages, 5410 KiB  
Article
Mechanical Properties of White Metal on SCM440 Alloy Steel by Laser Cladding Treatment
by Jae-Il Jeong, Jong-Hyoung Kim, Si-Geun Choi, Young Tae Cho, Chan-Kyu Kim and Ho Lee
Appl. Sci. 2021, 11(6), 2836; https://doi.org/10.3390/app11062836 - 22 Mar 2021
Cited by 4 | Viewed by 2747
Abstract
The bearing is a machine element that plays an important role in rotating the shaft of a machine while supporting its weight and load. Numerous bearings have been developed to improve durability and life, depending on the functions and operating conditions in which [...] Read more.
The bearing is a machine element that plays an important role in rotating the shaft of a machine while supporting its weight and load. Numerous bearings have been developed to improve durability and life, depending on the functions and operating conditions in which they are desired. White metal is one of method to improve durability that is soft and bonded to the inner surface of the bearing to protect the bearing shaft. Currently, the centrifugal casting process is used as a white metal lamination method, but it involves problems such as long processing times, high defect rates and harmful health effects. In this paper, a laser cladding treatment is applied to bond powdered white metal to SCM440 alloy steel, which is used as bearing material in terms of replacing the risks of a centrifugal process. In order to understand whether laser cladding is a suitable process, this paper compares the mechanical properties of white metal produced on SCM440 alloy steel by centrifugal casting and the laser cladding process. The laser power, powder feed rate and laser head speed factors are varied to understand the mechanical properties and measure the hardness using micro Vickers and conduct field emission scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction and friction testing to understand the mechanical properties and surface characteristics. Based on the results, the hardness values of the cladding (white metal) layer ranged between 24 and 26 HV in both the centrifugal casting and laser cladding methods. However, the hardness of the white metal produced by laser cladding at about a depth of 0.1 mm rose rapidly in the cladding process, forming a heat-affected zone (HAZ) with an average hardness value of 200 HV at a laser power of 1.1 kW, 325 HV at 1.3 kW and 430 HV at 1.5 kW. The surface friction testing results revealed no significant differences in the friction coefficient between the centrifugal casting and laser cladding methods, which allows the assumption that the processing method does not significantly influence the friction coefficient. Full article
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