Giuseppe Casalino

Bio: Giuseppe Casalino is an academic researcher from Instituto Politécnico Nacional. The author has contributed to research in topics: Welding & Laser beam welding. The author has an hindex of 27, co-authored 130 publications receiving 2511 citations. Previous affiliations of Giuseppe Casalino include Polytechnic University of Bari.

Experimental investigation and statistical optimisation of the selective laser melting process of a maraging steel

Abstract: Selective Laser Melting (SLM) is an Additive Manufacturing process (AM) that built parts from powder using a layer-by-layer deposition technique. The control of the parameters that influence the melting and the amount of energy density involved in the process is paramount in order to get valuable parts. The objective of this paper is to perform an experimental investigation and a successive statistical optimization of the parameters of the selective laser melting process of the 18Ni300 maraging steel. The experimental investigation involved the study of the microstructure, the mechanical and surface properties of the laser maraging powder. The outcomes of experimental study demonstrated that the hardness, the mechanical strength and the surface roughness correlated positively to the part density. Parts with relative density higher than 99% had a very low porosity that presented closed and regular shaped pores. The statistical optimization determined that the best part properties were produced with the laser power bigger than 90 W and the velocity smaller than 220 mm/s.

Effect of power distribution on the weld quality during hybrid laser welding of an Al-Mg alloy

Abstract: This paper treats of the analysis of the effect of arc and laser powers on the quality of the arc assisted fiber laser welding of an Al–Mg alloy in the butt configuration. Grain size, weld geometry defects, porosity, and magnesium loss were measured. Magnesium content of the fused zone decreased as the laser power increased while the porosity increased with laser power. Microhardness profiles and tensile properties were explained on the basis of the joint microstructure and defects and related to the power distribution. The porosity level and Mg content in the fused zone affected both tensile strength and ductility. The power distribution that stabilized the welding process and minimize the weld porosity was defined.

Additive manufacturing (3D printing): A review of materials, methods, applications and challenges

Abstract: Freedom of design, mass customisation, waste minimisation and the ability to manufacture complex structures, as well as fast prototyping, are the main benefits of additive manufacturing (AM) or 3D printing. A comprehensive review of the main 3D printing methods, materials and their development in trending applications was carried out. In particular, the revolutionary applications of AM in biomedical, aerospace, buildings and protective structures were discussed. The current state of materials development, including metal alloys, polymer composites, ceramics and concrete, was presented. In addition, this paper discussed the main processing challenges with void formation, anisotropic behaviour, the limitation of computer design and layer-by-layer appearance. Overall, this paper gives an overview of 3D printing, including a survey on its benefits and drawbacks as a benchmark for future research and development.