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Journal ArticleDOI

Influence of process parameters on surface roughness of aluminum parts produced by DMLS.

TL;DR: In this paper, a model based on an L18 orthogonal array of Taguchi design was created to perform experimental planning and the upper surfaces of the samples were analyzed before and after shot peening.
Abstract: Direct metal laser sintering (DMLS) is an additive manufacturing technique for the fabrication of near net-shaped parts directly from computer-aided design data by melting together different layers with the help of a laser source. This paper presents an investigation of the surface roughness of aluminum samples produced by DMLS. A model based on an L18 orthogonal array of Taguchi design was created to perform experimental planning. Some input parameters, namely laser power, scan speed, and hatching distance were selected for the investigation. The upper surfaces of the samples were analyzed before and after shot peening. The morphology was analyzed by means of field emission scanning electron microscope. Scan speed was found to have the greatest influence on the surface roughness. Further, shot peening can effectively reduce the surface roughness.
Citations
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Journal ArticleDOI
TL;DR: A review of the emerging research on additive manufacturing of metallic materials is provided in this article, which provides a comprehensive overview of the physical processes and the underlying science of metallurgical structure and properties of the deposited parts.

4,192 citations


Cites background from "Influence of process parameters on ..."

  • ...s on build surface [203] (d) balling effect [195] (e) effect of heat input on surface roughness [205,206] (f) effect of powder diameter on surface...

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  • ...17(e) shows a collection of surface roughness data from independent literature [205,206] for three alloys plotted against linear heat input....

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Journal ArticleDOI
TL;DR: Selective laser melting (SLM) is a particular rapid prototyping, 3D printing, or additive manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders as mentioned in this paper.
Abstract: Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component is built by selectively melting and fusing powders within and between layers. The SLM technique is also commonly known as direct selective laser sintering, LaserCusing, and direct metal laser sintering, and this technique has been proven to produce near net-shape parts up to 99.9% relative density. This enables the process to build near full density functional parts and has viable economic benefits. Recent developments of fibre optics and high-power laser have also enabled SLM to process different metallic materials, such as copper, aluminium, and tungsten. Similarly, this has also opened up research opportunities in SLM of ceramic and composite materials. The review presents the SLM process and some of the common physical phenomena associated with this AM technology. It then focuses on the following a...

1,455 citations

Journal ArticleDOI
TL;DR: A comprehensive analysis of surface texture metrology for metal additive manufacturing has been performed in this paper, where the results of this analysis are divided into sections that address specific areas of interest: industrial domain; additive manufacturing processes and materials; types of surface investigated; surface measurement technology and surface texture characterisation.
Abstract: A comprehensive analysis of literature pertaining to surface texture metrology for metal additive manufacturing has been performed. This review paper structures the results of this analysis into sections that address specific areas of interest: industrial domain; additive manufacturing processes and materials; types of surface investigated; surface measurement technology and surface texture characterisation. Each section reports on how frequently specific techniques, processes or materials have been utilised and discusses how and why they are employed. Based on these results, possible optimisation of methods and reporting is suggested and the areas that may have significant potential for future research are highlighted.

537 citations


Cites background from "Influence of process parameters on ..."

  • ...…L. Blunta, R.K. Leachb, J.S. Taylorc a EPSCRC Centre for Innovation in Advanced Metrology, University of Huddersfield, UK b Manufacturing Metrology Team, Faculty of Engineering, University of Nottingham, UK c Center for Precision Metrology, University of North Carolina at Charlotte and Lawrence...

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Journal ArticleDOI
TL;DR: In this paper, the effect of three different powder granulations on the resulting part density, surface quality and mechanical properties of the materials produced was investigated, and the scan surface quality was compared with two layer thicknesses of 30 and 45μm.
Abstract: Purpose – A recent study confirmed that the particle size distribution of a metallic powder material has a major influence on the density of a part produced by selective laser melting (SLM). Although it is possible to get high density values with different powder types, the processing parameters have to be adjusted accordingly, affecting the process productivity. However, the particle size distribution does not only affect the density but also the surface quality and the mechanical properties of the parts. The purpose of this paper is to investigate the effect of three different powder granulations on the resulting part density, surface quality and mechanical properties of the materials produced.Design/methodology/approach – The scan surface quality and mechanical properties of three different particle size distributions and two layer thicknesses of 30 and 45 μm were compared. The scan velocities for the different powder types have been adjusted in order to guarantee a part density≥99.5 per cent.Findings ...

450 citations

Journal ArticleDOI
02 Jan 2017
TL;DR: This paper provides an overview on the main additive manufacturing/3D printing technologies suitable for many satellite applications and, in particular, radio-frequency components.
Abstract: This paper provides an overview on the main additive manufacturing/3D printing technologies suitable for many satellite applications and, in particular, radio-frequency components. In fact, nowadays they have become capable of producing complex net-shaped or nearly net-shaped parts in materials that can be directly used as functional parts, including polymers, metals, ceramics, and composites. These technologies represent the solution for low-volume, high-value, and highly complex parts and products.

399 citations


Cites background from "Influence of process parameters on ..."

  • ...The SLM process parameters can be useful in improving surface quality [85]–[88] , but it is usually inferior than the conventional manufacturing....

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References
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Book
12 Mar 2014
TL;DR: In this paper, the 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).
Abstract: 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).

1,539 citations

Journal ArticleDOI
TL;DR: In this paper, a mixture of different types of particles (Fe, Ni, Cu and Fe3P) specially developed for selective laser sintering (SLS) is described.

1,342 citations


"Influence of process parameters on ..." refers background in this paper

  • ...However, if these values become too high, large amounts of material vaporiza-tion can occur with recoil pressures that disrupt the melt pool surface and increase again the top Ra [34]....

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Journal ArticleDOI
TL;DR: In this article, the authors describe which types of laser-induced consolidation can be applied to what type of material, and demonstrate that although SLS/SLM can process polymers, metals, ceramics and composites, quite some limitations and problems cause the palette of applicable materials still to be limited.

1,241 citations

28 Sep 2014

860 citations


"Influence of process parameters on ..." refers methods in this paper

  • ...Taguchi method [28] is based on orthogonal array experiments which provide more reduced variance for the experiment with optimum settings of control parameters....

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  • ...Taguchi [28] developed a family of FFE matrices (an orthogonal array) that has generally been adopted to optimize the design parameters and significantly minimize the overall testing time and experimental costs following a systematic approach to confine the number of experiments and tests [29, 30]....

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BookDOI
09 May 2006
TL;DR: In this paper, the authors present a discussion of the potential of rapid manufacturing in the automotive industry and present a case study of how to modify a garden fork handle in order to make it more efficient.
Abstract: List of Contributors. Editors. Foreword (Terry Wohlers). 1 Introduction to Rapid Manufacturing (Neil Hopkinson, Richard Hague and Phill Dickens). 1.1 Definition of Rapid Manufacturing. 1.2 Latitude of Applications. 1.3 Design Freedom. 1.4 Economic for Volumes down to One. 1.5 Overcoming the Legacy of Rapid Prototyping. 1.6 A Disruptive Technology. 1.7 A Breakdown of the Field of Rapid Manufacturing. 2 Unlocking the Design Potential of Rapid Manufacturing (Richard Hague). 2.1 Introduction. 2.2 Potential of Rapid Manufacturing on Design. 2.3 Geometrical Freedom. 2.4 Material Combinations. 2.5 Summary. 3 Customer Input and Customisation (R.I. Campbell). 3.1 Introduction. 3.2 Why Is Customer Input Needed? 3.3 What Input can the Customer Make? 3.4 How Can Customer Input Be Captured? 3.5 Using Customer Input within the Design Process. 3.6 What Is Customisation? 3.7 Determining Which Features to Customise. 3.8 Additional Customisation Issues. 3.9 Case Study - Customising Garden Fork Handles. 3.10 Conclusions. 4 CAD and Rapid Manufacturing (Rik Knoppers and Richard Hague). 4.1 Introduction. 4.2 CAD Background. 4.3 Relations between CAD and Rapid Manufacturing. 4.4 Future Developments Serving Rapid Manufacturing. 4.5 CAD for Functionally Graded Materials (FGMs). 4.6 Conclusion. 5 Emerging Rapid Manufacturing Processes (Neil Hopkinson and Phill Dickens). 5.1 Introduction. 5.2 Liquid-Based Processes. 5.3 Powder-Based Processes. 5.4 Solid-Based Processes. 6 Materials Issues in Rapid Manufacturing (David L. Bourell). 6.1 Role of Materials in Rapid Manufacturing. 6.2 Viscous Flow. 6.3 Photopolymerization. 6.4 Sintering. 6.5 Infiltration. 6.6 Mechanical Properties of RM Parts. 6.7 Materials for RM Processes. 6.8 The Future of Materials in Rapid Manufacturing. 7 Functionally Graded Materials (Poonjolai Erasenthiran and Valter Beal). 7.1 Introduction. 7.2 Processing Technologies. 7.3 Rapid Manufacturing of FGM Parts - Laser Fusion. 7.4 Modelling and Software Issues. 7.5 Characterisation of Properties. 7.6 Deposition Systems. 7.7 Applications. 8 Materials and Process Control for Rapid Manufacture (Tim Gornet). 8.1 Introduction. 8.2 Stereolithography. 8.3 Selective Laser Sintering. 8.4 Fused Deposition Modeling. 8.5 Metal-Based Processes. 9 Production Economics of Rapid Manufacture (Neil Hopkinson). 9.1 Introduction. 9.2 Machine Costs. 9.3 Material Costs. 9.4 Labour Costs. 9.5 Comparing the Costs of Rapid Manufacture with Injection Moulding. 10 Management and Implementation of Rapid Manufacturing (Chris Tuck and Richard Hague). 10.1 Introduction. 10.2 Costs of Manufacture. 10.3 Overhead Allocation. 10.4 Business Costs. 10.5 Stock and Work in Progress. 10.6 Location and Distribution. 10.7 Supply Chain Management. 10.8 Change. 10.9 Conclusions. 11 Medical Applications (Russ Harris and Monica Savalani). 11.1 Introduction. 11.2 Pre-Surgery RM. 11.3 Orthodontics. 11.4 Drug Delivery Devices. 11.5 Limb Prosthesis. 11.6 Specific Advances in Computer Aided Design (CAD). 11.7 In Vivo Devices. 12 Rapid Manufacturing in the Hearing Industry (Martin Masters, Therese Velde and Fred McBagonluri). 12.1 The Hearing Industry. 12.2 Manual Manufacturing. 12.3 Digital Manufacturing. 12.4 Scanning. 12.5 Electronic Detailing. 12.6 Electronic Modeling. 12.7 Fabrication. 12.8 Equipment. 12.9 Selective Laser Sintering (SLS). 12.10 Stereolithography Apparatus (SLA). 12.11 Raster-Based Manufacturing. 12.12 Materials. 12.13 Conclusion. 13 Automotive Applications (Graham Tromans). 13.1 Introduction. 13.2 Formula 1. 13.3 Cooling Duct. 13.4 The 'Flickscab'. 13.5 NASCAR. 13.6 Formula Student. 14 Rapid Manufacture in the Aeronautical Industry (Brad Fox). 14.1 Opportunity. 14.2 Overview. 14.3 Historical Perspective. 14.4 Aeronautical Requirements for RM. 14.5 Why RM Is Uniquely Suited to the Aeronautical Field. 14.6 Acceptable Technologies. 14.7 Qualifying RM Systems. 14.7.1 Qualifying SLS at British Aerospace (BAe). 14.7.2 Qualifying SLS at Northrop Grumman. 14.8 Summary. 14.9 Case Studies. 15 Aeronautical Case Studies using Rapid Manufacture (John Wooten). 15.1 Introduction. 15.2 Problem and Proposed Solution. 15.3 Benefits of a Rapid Manufacture Solution. 15.4 Pre-Production Program. 15.5 Production. 15.6 Summary. 16 Space Applications (Roger Spielman). 16.1 Introduction. 16.2 Building the Team. 16.3 Quality Assurance. 16.4 How to 'Qualify' a Part Created Using This Process. 16.5 Producing Hardware. 17 Additive Manufacturing Technologies for the Construction Industry (Rupert Soar). 17.1 Introduction. 17.2 The Emergence of Freeform Construction. 17.3 Freeform Construction Processes: A Matter of Scale. 17.4 Conclusions. 18 Rapid Manufacture for the Retail Industry (Janne Kyttanen). 18.1 Introduction. 18.2 Fascinating Technology with Little Consumer Knowledge. 18.3 The Need for Rapid Prototyping to Change to Rapid Manufacturing. 18.4 Rapid Manufacturing Retail Applications. 18.4.1 Lighting. 18.4.2 Three-Dimensional Textiles. 18.5 Mass Customisation. 18.5.1 Mass Customised Retail Products. 18.5.2 Future Posibilities of Mass Customised RM Products. 18.5.3 Limitations and Possibilities. 18.6 Experimentation and Future Applications. Index.

807 citations