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Industrial Additive Manufacturing Process Planning: Process Evaluation, Metrology, and Post-Processing Techniques

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (30 June 2020) | Viewed by 22395

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Dr. Hector R. Siller

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Department of Mechanical Engineering, University of North Texas, Denton, TX 76201, USA
Interests: additive manufacturing; metrology; micro-manufacturing; high-performance machining
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Dear Colleagues,

Additive manufacturing processes have been studied from different fields, including powder metallurgy, surface engineering, thermal engineering, and other areas of scientific research. Nevertheless, at present, as the adoption of these processes in real manufacturing operations is increasing, engineers are demanding practical information for process calibration, evaluation, metrology, and post-processing techniques in order to meet the product specifications, particularly in the aeronautic, automotive, and biomedical industries. The use of advanced engineered alloys in additive manufacturing is not a guarantee of a good mechanical performance, due to the porosity and lack of uniformity in comparison with traditional manufacturing processes. Hence, the necessity to perform post-processing operations is imperative, and the development of different evaluation strategies should be connected to product realization.

The aim of this Special Issue is to present the latest research and development in the field of industrial additive manufacturing process planning, and including all the taxonomy of processing technologies like powder bed fusion, direct energy deposition, binder jetting, ultrasonic additive manufacturing, and friction stir processing, among others.

We are most interested in high-quality papers which explore the evaluation of different process parameters and the use of post-processing technologies like surface treatments, hot isostatic pressing and advanced heat treatments for the improvement of mechanical performance and corrosion resistance. Furthermore, we encourage the submission of papers dedicated to the exploration of different metrology techniques like x-ray computed tomography and confocal microscopy in the dimensional and surface quality assessment of additively manufactured parts.

Dr. Hector R. Siller
Guest Editor

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Keywords

Additive manufacturing
Process planning
Post-processing techniques
Metallic alloys
Metrology
Corrosion resistance
Mechanical performance

Published Papers (5 papers)

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16 pages, 4698 KiB

Open AccessArticle

Extended CT Void Analysis in FDM Additive Manufacturing Components

by Adriana Hernandez-Contreras, Leopoldo Ruiz-Huerta, Alberto Caballero-Ruiz, Verena Moock and Hector R. Siller

Materials 2020, 13(17), 3831; https://doi.org/10.3390/ma13173831 - 30 Aug 2020

Cited by 24 | Viewed by 2980

Abstract

Additive manufacturing (AM) is the term for a number of processes for joining materials to build physical components from a digital 3D model. AM has multiple advantages over other construction techniques, such as freeform, customization, and waste reduction. However, AM components have been evaluated by destructive and non-destructive testing and have shown mechanical issues, such as reduced resistance, anisotropy and voids. The build direction affects the mechanical properties of the built part, including voids of different characteristics. The aim of this work is an extended analysis of void shape by means of X-ray computed tomography (CT) applied to fused deposition modeling (FDM) samples. Furthermore, a relation between the tensile mechanical properties and digital void measurements is established. The results of this work demonstrate that void characteristics such as quantity, size, sphericity and compactness show no obvious variations between the samples. However, the angle between the main void axis and the mechanical load axis α shows a relation for FDM components: when its mean value μ(α) is around 80 (degrees) the yield strength and Young’s modulus are reduced. These results lead to the formulation of a novel criterion that predicts the mechanical behavior of AM components. Full article

(This article belongs to the Special Issue Industrial Additive Manufacturing Process Planning: Process Evaluation, Metrology, and Post-Processing Techniques)

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15 pages, 1983 KiB

Open AccessArticle

A Sensitivity Analysis-Based Parameter Optimization Framework for 3D Printing of Continuous Carbon Fiber/Epoxy Composites

by Hong Xiao, Wei Han, Yueke Ming, Zhongqiu Ding and Yugang Duan

Materials 2019, 12(23), 3961; https://doi.org/10.3390/ma12233961 - 29 Nov 2019

Cited by 18 | Viewed by 3696

Abstract

Three-dimensional printing of continuous carbon fiber/epoxy composites (CCF/EPCs) is an emerging additive manufacturing technology for fiber-reinforced polymer composites and has wide application prospects. However, the 3D printing parameters and their relationship with the mechanical properties of the final printed samples have not been fully investigated in a computational and quantifiable way. This paper presents a sensitivity analysis (SA)-based parameter optimization framework for the 3D printing of CCF/EPCs. A surrogate model for a process parameter–mechanical property relationship was established by support vector regression (SVR) analysis of the experimental data on flexural strength and flexural modulus under different process parameters. An SA was then performed on the SVR surrogate model to calculate the importance of each individual 3D printing parameter on the mechanical properties of the printed samples. Based on the SA results, the optimal 3D printing parameters and the corresponding flexural strength and flexural modulus of the printed samples were predicted and verified by experiments. The results showed that the proposed framework can serve as a high-accuracy tool to optimize the 3D printing parameters for the additive manufacturing of CCF/EPCs. Full article

(This article belongs to the Special Issue Industrial Additive Manufacturing Process Planning: Process Evaluation, Metrology, and Post-Processing Techniques)

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10 pages, 1151 KiB

Open AccessArticle

Decision Tree Methods for Predicting Surface Roughness in Fused Deposition Modeling Parts

by Juan M. Barrios and Pablo E. Romero

Materials 2019, 12(16), 2574; https://doi.org/10.3390/ma12162574 - 12 Aug 2019

Cited by 41 | Viewed by 4286

Abstract

3D printing using fused deposition modeling (FDM) includes a multitude of control parameters. It is difficult to predict a priori what surface finish will be achieved when certain values are set for these parameters. The objective of this work is to compare the models generated by decision tree algorithms (C4.5, random forest, and random tree) and to analyze which makes the best prediction of the surface roughness in polyethylene terephthalate glycol (PETG) parts printed in 3D using the FDM technique. The models have been created using a dataset of 27 instances with the following attributes: layer height, extrusion temperature, print speed, print acceleration, and flow rate. In addition, a dataset has been created to evaluate the models, consisting of 15 additional instances. The models generated by the random tree algorithm achieve the best results for predicting the surface roughness in FDM parts. Full article

(This article belongs to the Special Issue Industrial Additive Manufacturing Process Planning: Process Evaluation, Metrology, and Post-Processing Techniques)

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15 pages, 2080 KiB

Open AccessArticle

Improvement of Surface Roughness and Hydrophobicity in PETG Parts Manufactured via Fused Deposition Modeling (FDM): An Application in 3D Printed Self–Cleaning Parts

by Juan M. Barrios and Pablo E. Romero

Materials 2019, 12(15), 2499; https://doi.org/10.3390/ma12152499 - 06 Aug 2019

Cited by 47 | Viewed by 6571

Abstract

The fused deposition modeling (FDM) technique is used today by companies engaged in the fabrication of traffic signs for the manufacture of light-emitting diode LED spotlights. In this sector, the surface properties of the elements used (surface finish, hydrophobic features) are decisive because surfaces that retain little dirt and favor self–cleaning behavior are needed. A design of experiments (L27) with five factors and three levels has been carried out. The factors studied were: Layer height (LH), print temperature (T), print speed (PS), print acceleration (PA), and flow rate (F). Polyethylene terephthalate glycol (PETG) specimens of 25.0 × 25.0 × 2.4 mm have been printed and, in each of them, the surface roughness (R_a,0, R_a,90), sliding angle (SA₀, SA₉₀), and contact angle (CA₀, CA₉₀) in both perpendicular directions have been measured. Taguchi and ANOVA analysis shows that the most influential variables in this case are printing acceleration for R_{a, 0} (p–value = 0.052) and for SA₀ (p–value = 0.051) and flow rate for R_{a, 90} (p–value = 0.001) and for SA₉₀ (p–value = 0.012). Although the ANOVA results for the contact angle are not significant, specimen 8 (PA = 1500 mm/s² and flow rate F = 110%) and specimen 10 (PA =1500 mm/s² and F = 100%) have reached contact angle values above or near the limit value for hydrophobia, respectively. Full article

(This article belongs to the Special Issue Industrial Additive Manufacturing Process Planning: Process Evaluation, Metrology, and Post-Processing Techniques)

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19 pages, 2215 KiB

Open AccessArticle

Prediction and Characteristics of Angular Distortion in Multi-Layer Butt Welding

by Woo-Jae Seong

Materials 2019, 12(9), 1435; https://doi.org/10.3390/ma12091435 - 02 May 2019

Cited by 10 | Viewed by 4331

Abstract

Multi-layer welding involves the process of stacking many beads, so it requires much time and effort to predict the deformation through experimentation or numerical analysis. In this study, a systematic method for predicting transverse angular distortion in multi-layer butt welding has been proposed. First, the database was established through bead-on-plate welding experiments, which consisted of the relationship between welding conditions, the bead geometry, the material thickness, and the angular distortion. Then, when the arbitrary welding conditions and the shape of the butt joint were input, the method calculated the angular distortion per pass using the geometric principle and the database. The obtained prediction curves were verified with the V-groove welding experimental results. In addition, the characteristics of angular distortion in multi-layer butt welding were discussed. It was found that the angular distortion curve is a function of the number of passes and groove geometry. This algorithm is based on a numerical approach that saves computational time using databases and geometry, so it is suitable for industrial applications. Full article

(This article belongs to the Special Issue Industrial Additive Manufacturing Process Planning: Process Evaluation, Metrology, and Post-Processing Techniques)

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