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JMMP
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Hybrid Manufacturing
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Hybrid Manufacturing

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: closed (31 December 2023) | Viewed by 13344

Special Issue Editors

Prof. Dr. Abhijit Chandra

E-Mail Website
Guest Editor
Mechanical Engineering, Iowa State University, Ames, IA 50011, USA
Interests: mechanics; manufacturing; data science
Dr. Jonghyun Lee

E-Mail Website
Guest Editor
Mechanical Engineering, Iowa State University, Ames, IA 50011, USA
Interests: additive manufacturing; thermophysical properties; transport phenomena in molten metals; crystallization

Special Issue Information

Dear Colleagues,

Recent growth in engineering knowledge and technologies has evoked rapid advancement in multifarious fields. However, the unavailability of suitable materials and manufacturing processes has impeded such advancements. The advantages of the superior characteristics of a material are often mitigated by added processing complexity and manufacturing costs. Hybrid manufacturing attempts to alleviate these difficulties by accentuating the strengths of individual processing avenues, while suppressing the drawbacks. For example, chemical–mechanical polishing enables the planarization of hard wafer materials by a chemical reaction with slurry while enhancing both planarization quality and throughput. Laser-assisted cold spray enables the deposition of metals of high specific stiffness with minimal porosity via the pre- or post-heating of a substrate material.

In this context, this issue focuses on the recent advances in hybrid manufacturing. The collection of state of the art hybrid manufacturing processes around the world should provide the current trends of hybrid manufacturing and help chart its future direction.

Prof. Dr. Abhijit Chandra
Dr. Jonghyun Lee
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

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. Journal of Manufacturing and Materials Processing 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 1800 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

  • manufacturing
  • hybrid
  • multi-physics
  • synergistic
  • combinations

Published Papers (5 papers)

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Research

11 pages, 7399 KiB  
Article
Printing Cu on a Cold-Sprayed Cu Plate via Selective Laser Melting—Hybrid Additive Manufacturing
by Qing Chai, Chaoxin Jiang, Chunjie Huang, Yingchun Xie, Xingchen Yan, Rocco Lupoi, Chao Zhang, Peter Rusinov and Shuo Yin
J. Manuf. Mater. Process. 2023, 7(6), 188; https://doi.org/10.3390/jmmp7060188 - 24 Oct 2023
Viewed by 1529
Abstract
The development of the additive manufacturing (AM) technology proffers challenging requirements for forming accuracy and efficiency. In this paper, a hybrid additive manufacturing technology combining fusion-based selective laser melting (SLM) and solid-state cold spraying (CS) was proposed in order to enable the fast [...] Read more.
The development of the additive manufacturing (AM) technology proffers challenging requirements for forming accuracy and efficiency. In this paper, a hybrid additive manufacturing technology combining fusion-based selective laser melting (SLM) and solid-state cold spraying (CS) was proposed in order to enable the fast production of near-net-shape metal parts. The idea is to fabricate a bulk deposit with a rough contour first via the “fast” CS process and then add fine structures and complex features through “slow” SLM. The experimental results show that it is feasible to deposit an SLM part onto a CS part with good interfacial bonding. However, the CS parts must be subject to heat treatment to improve their cohesion strength before being sending for SLM processing. Otherwise, the high tensile residual stress generated during the SLM process will cause fractures and cracks in the CS part. After heat treatment, pure copper deposited by CS undergoes grain growth and recrystallization, resulting in improved cohesive strength and the release of the residual stress in the CS parts. The tensile test on the SLM/CS interfacial region indicates that the bonding strength increased by 38% from 45 ± 7 MPa to 62 ± 1 MPa after the CS part is subject to heat treatment, and the SLM/CS interfacial bonding strength is higher than the CS parts. This study demonstrates that the proposed hybrid AM process is feasible and promising for manufacturing free-standing SLM-CS components. Full article
(This article belongs to the Special Issue Hybrid Manufacturing)
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14 pages, 13396 KiB  
Article
Freeform Hybrid Manufacturing: Binderjet, Structured Light Scanning, Confocal Microscopy, and CNC Machining
by Jake Dvorak, Dustin Gilmer, Ross Zameroski, Aaron Cornelius and Tony Schmitz
J. Manuf. Mater. Process. 2023, 7(2), 79; https://doi.org/10.3390/jmmp7020079 - 18 Apr 2023
Cited by 2 | Viewed by 1726
Abstract
This paper describes a hybrid manufacturing approach for silicon carbide (SiC) freeform surfaces using binder jet additive manufacturing (BJAM) to print the preform and machining to obtain the design geometry. Although additive manufacturing (AM) techniques such as BJAM allow for the fabrication of [...] Read more.
This paper describes a hybrid manufacturing approach for silicon carbide (SiC) freeform surfaces using binder jet additive manufacturing (BJAM) to print the preform and machining to obtain the design geometry. Although additive manufacturing (AM) techniques such as BJAM allow for the fabrication of complex geometries, additional machining or grinding is often required to achieve the desired surface finish and shape. Hybrid manufacturing has been shown to provide an effective solution. However, hybrid manufacturing also has its own challenges, depending on the combination of processes. For example, when the subtractive and additive manufacturing steps are performed sequentially on separate systems, it is necessary to define a common coordinate system for part transfer. This can be difficult because AM preforms do not inherently contain features that can serve as datums. Additionally, it is important to confirm that the intended final geometry is contained within the AM preform. The approach described here addresses these challenges by using structured light scanning to create a stock model for machining. Results show that a freeform surface was machined with approximately 70 µm of maximum deviation from that which was planned. Full article
(This article belongs to the Special Issue Hybrid Manufacturing)
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14 pages, 3297 KiB  
Article
Hybrid Manufacturing of Conformal Cooling Channels for Tooling
by Thomas Feldhausen, Mithulan Paramanathan, Jesse Heineman, Ahmed Hassen, Lauren Heinrich, Rebecca Kurfess, Kenton Fillingim, Kyle Saleeby and Brian Post
J. Manuf. Mater. Process. 2023, 7(2), 74; https://doi.org/10.3390/jmmp7020074 - 12 Apr 2023
Cited by 4 | Viewed by 2511
Abstract
Computer-aided manufacturing (CAM) techniques for hybrid manufacturing have led to new application areas in the manufacturing industry. In the tooling industry, cooling channels are used to enable specific heating and cooling cycles to improve the performance of the process. These internal cooling channels [...] Read more.
Computer-aided manufacturing (CAM) techniques for hybrid manufacturing have led to new application areas in the manufacturing industry. In the tooling industry, cooling channels are used to enable specific heating and cooling cycles to improve the performance of the process. These internal cooling channels have been designed with limited manufacturing processes in mind, so, until recently, they were often straight in shape for cross-drilling operations and manufactured from a cast billet. To show a novel application of this common technology, a tool with integrated conformal cooling channels was manufactured using hybrid manufacturing (blown-powder DED and CNC machining) techniques. The computer-aided manufacturing strategy used, and the lessons learned are presented and discussed to enable future work in this industrial application space. Full article
(This article belongs to the Special Issue Hybrid Manufacturing)
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19 pages, 3607 KiB  
Article
Implementation of Sacrificial Support Structures for Hybrid Manufacturing of Thin Walls
by Derek Vaughan, Christopher Saldana, Thomas Kurfess and Andrzej Nycz
J. Manuf. Mater. Process. 2022, 6(4), 70; https://doi.org/10.3390/jmmp6040070 - 30 Jun 2022
Cited by 3 | Viewed by 2062
Abstract
Thin-walled features can be difficult to produce with traditional machining methods which often rely on excess stock material for stiffness. This challenge is increased in hybrid manufacturing where the feature is already near net shape before machining. Significant workpiece deflection can result in [...] Read more.
Thin-walled features can be difficult to produce with traditional machining methods which often rely on excess stock material for stiffness. This challenge is increased in hybrid manufacturing where the feature is already near net shape before machining. Significant workpiece deflection can result in poor geometric and surface finish tolerances on the finished part. A potential solution to this problem is to implement sacrificial support structures to the as-printed geometry. The supports are then machined away during the finishing portion of the hybrid process. In the present work, several different design parameters for these sacrificial supports were evaluated to determine their impact on the quality of representative thin wall geometry samples. The angle, height, and spacing of triangular support structures were varied for each sample and then machined and examined. The addition of these supports relative to an unsupported configuration provided a deflection reduction of around 0.2 mm. Surface roughness was improved by approximately 1.5 µm. Increasing values of support height were found to correspond to reduced wall deflection. Similarly, decreasing values of support angle and support spacing improved geometric accuracy. Efficiency comparisons showed that increases in print time corresponded to rapidly diminishing gains in geometric accuracy but continued to improve surface roughness. Implications for hybrid finishing of additively manufactured thin-walled structures is briefly discussed. Full article
(This article belongs to the Special Issue Hybrid Manufacturing)
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27 pages, 6045 KiB  
Article
Benchmarking of 316L Stainless Steel Manufactured by a Hybrid Additive/Subtractive Technology
by Sheida Sarafan, Priti Wanjara, Javad Gholipour, Fabrice Bernier, Mahmoud Osman, Fatih Sikan, Josh Soost, Robert Amos, Prakash Patnaik and Mathieu Brochu
J. Manuf. Mater. Process. 2022, 6(2), 30; https://doi.org/10.3390/jmmp6020030 - 05 Mar 2022
Cited by 8 | Viewed by 4574
Abstract
This research study investigated the hybrid processing of 316L stainless steel using laser powder bed (LPB) processing with high-speed machining in the same build envelope. Benchmarking at four laser powers (160 W, 240 W, 320 W, and 380 W) was undertaken by building [...] Read more.
This research study investigated the hybrid processing of 316L stainless steel using laser powder bed (LPB) processing with high-speed machining in the same build envelope. Benchmarking at four laser powers (160 W, 240 W, 320 W, and 380 W) was undertaken by building additively with machining passes integrated sequentially after every ten deposited layers, followed by the final finishing of select surfaces. The final geometry was inspected against the computer-aided design (CAD) model and showed deviations smaller than 280 µm for the as-built and machined surfaces, which demonstrate the good efficacy of hybrid processing for the net-shape manufacturing of stainless steel products. The arithmetic average roughness values for the printed surfaces, Ra (linear) and Sa (surface), were 11.4 um and 14.9 um, respectively. On the other hand, the vertical and horizontal machined surfaces had considerably lower roughness, with Ra and Sa values ranging between 0.33 µm and 0.70 µm. The 160 W coupon contained layered, interconnected lack of fusion defects which affected the density (7.84 g·cm−3), yield strength (494 MPa), ultimate tensile strength (604 MPa), Young’s modulus (175 GPa), and elongation at break (17.3%). By contrast, at higher laser powers, near-full density was obtained for the 240 W (7.96 g·cm−3), 320 W (7.94 g·cm−3), and 380 W (7.92 g·cm−3) conditions. This, combined with the isolated nature of the small pores, led to the tensile properties surpassing the requirements stipulated in ASTM F3184—16 for 316L stainless steel. Full article
(This article belongs to the Special Issue Hybrid Manufacturing)
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