Additive manufacturing of metallic components – Process, structure and properties

Unlike conventional materials removal methods, additive manufacturing (AM) is based on a novel materials incremental manufacturing philosophy. Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser. The current development focus of AM is to produce complex shaped functional metallic components, including metals, alloys and metal matrix composites (MMCs), to meet demanding requirements from aerospace, defence, automotive and biomedical industries. Laser sintering (LS), laser melting (LM) and laser metal deposition (LMD) are presently regarded as the three most versatile AM processes. Laser based AM processes generally have a complex non-equilibrium physical and chemical metallurgical nature, which is material and process dependent. The influence of material characteristics and processing conditions on metallurgical mechanisms and resultant microstructural and mechanical properties of AM proc...

Laser additive manufacturing of metallic components: materials, processes and mechanisms

In the laser treatment of a workpiece (9), e.g. for surface hardening, melting, alloying, cladding, welding or cutting, the adverse effect of reflectivity of the surface, when a pure, monochromatic laser (6) is used, is remedied by the simultaneous application of a relatively shorter wavelength beam (1). The two beams (1)(5) may be combined by a beam coupler (4) or may reach the workpiece (9) by separate optical paths (not shown). The shorter wavelength beam (1) improves the coupling efficiency of the higher- powered laser beam (5).

Laser Material Processing

Thirty years into its development, additive manufacturing has become a mainstream manufacturing process. Additive manufacturing build up parts by adding materials one layer at a time based on a computerized 3D solid model. It does not require the use of fixtures, cutting tools, coolants, and other auxiliary resources. It allows design optimization and the producing of customized parts on-demand. Its advantages over conventional manufacturing have captivated the imagination of the public, reflected in recent mainstream publications that call additive manufacturing “the third industrial revolution.” This paper reviews the societal impact of additive manufacturing from a technical perspective. Abundance of evidences were found to support the promises of additive manufacturing in the following areas: (1) customized healthcare products to improve population health and quality of life, (2) reduced environmental impact for manufacturing sustainability, and (3) simplified supply chain to increase efficiency and responsiveness in demand fulfillment. In the mean time, the review also identified the need for further research in the areas of life-cycle energy consumption evaluation and potential occupation hazard assessment for additive manufacturing.

Additive manufacturing and its societal impact: a literature review

Residual stress is that which remains in a body that is stationary and at equilibrium with its surroundings. It can be very detrimental to the performance of a material or the life of a component. Alternatively, beneficial residual stresses can be introduced deliberately. Residual stresses are more difficult to predict than the in-service stresses on which they superimpose. For this reason, it is important to have reliable methods for the measurement of these stresses and to understand the level of information they can provide. In this paper, which is the first part of a two part overview, the effect of residual stresses on fatigue lifetimes and structural integrity are first summarised, followed by the definition and measurement of residual stresses. Different types of stress are characterised according to the characteristic length scale over which they self-equilibrate. By comparing this length to the gauge volume of each technique, the capability of a range of techniques is assessed. In the sec...

Residual stress. Part 1 – Measurement techniques

Understanding thermal behavior in the LENS process

Evaluation of an energy-based approach and a critical plane approach for predicting constant amplitude multiaxial fatigue life

A fiber optic sensor capable of measuring two independent components of transverse strain is described. The sensor consists of a single Bragg grating written into high-birefringent, polarization-maintaining optical fiber. When light from a broadband source is used to illuminate the sensor, the spectra of light reflected from the Bragg grating contain two peaks corresponding to the two orthogonal polarization modes of the fiber. Two independent components of transverse strain in the core of the fiber can be computed from the changes in wavelength of the two peaks if axial strain and temperature changes in the fiber are zero or known. Experiments were performed to determine the response of the sensor by loading an uncoated sensor in diametral compression over a range of fiber orientations relative to the loading. The results of these experiments were used with a finite element model to determine a calibration matrix relating the transverse strain in the sensor to the wavelength shifts of the Bragg peaks. The performance of the sensor was then verified by measuring the transverse strains produced by loading the fiber in a V-groove fixture.

A fiber optic sensor for transverse strain measurement

Holographic interferometry is used to determine in-plane radial displacements due to release of residual stresses by hole drilling. A method is derived for relating radial displacements measured in three directions of illumination to the state of residual stress, analogous to relations used in the conventional strain-rosette technique. Residual stress is produced by an interference fit of two circular tubes. Agreement between stress determined holographically with a computed value and with that determined by the conventional technique is good. Advantages of the holographic technique in overcoming various shortcomings of the conventional technique are discussed. A modification of the holographic technique involving data collection in only two directions of illumination is described.

Residual-stress determination through combined use of holographic interferometry and blind-hole drilling

A method is described for the rapid, accurate determination of residual stresses from a holographic interference fringe pattern. The pattern is generated by the displacement field caused by localized relief of residual stresses via the introduction of a small, shallow hole into the surface of a component or test specimen. The theoretical development of the holographic method is summarized. An example is given showing how the method can be applied to a typical experimentally observed fringe pattern to determine principal residual stresses and directions.

Drew V. Nelson

Papers

Understanding thermal behavior in the LENS process

Evaluation of an energy-based approach and a critical plane approach for predicting constant amplitude multiaxial fatigue life

A fiber optic sensor for transverse strain measurement

Residual-stress determination through combined use of holographic interferometry and blind-hole drilling

Residual-stress determination by single-axis holographic interferometry and hole drilling—Part I: Theory