Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing
TL;DR: In this paper, the state-of-the-art with respect to inspection methodologies compatible with additively manufactured (AM) processes is explored with the intention of identifying new avenues for research and proposing approaches to integration into future generations of AM systems.
About: This article is published in Materials & Design.The article was published on 2016-04-05 and is currently open access. It has received 1024 citations till now.
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TL;DR: Additive manufacturing (AM) is fundamentally different from traditional formative or subtractive manufacturing in that it is the closest to the bottom-up manufacturing where a structure can be built into its designed shape using a "layer-by-layer" approach rather than casting or forming by technologies such as forging or machining as discussed by the authors.
1,124 citations
TL;DR: A broad range of metal additive manufacturing (AM) technologies and reviews literatures on the anisotropy and heterogeneity of microstructure and mechanical properties for metal AM parts are presented in this paper.
799 citations
Cites background from "Review of in-situ process monitorin..."
...Such processing defects can range from ~50-500 μm in size [93]....
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...Many are actively conducting research in the area of in-situ process monitoring, to identify such material discontinuities during the manufacturing process [93]....
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01 Oct 2016-Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology
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
TL;DR: In this paper, a review of the literature and the commercial tools for insitu monitoring of powder bed fusion (PBF) processes is presented, focusing on the development of automated defect detection rules and the study of process control strategies.
Abstract: Despite continuous technological enhancements of metal Additive Manufacturing (AM) systems, the lack of process repeatability and stability still represents a barrier for the industrial breakthrough. The most relevant metal AM applications currently involve industrial sectors (e.g., aerospace and bio-medical) where defects avoidance is fundamental. Because of this, there is the need to develop novel in-situ monitoring tools able to keep under control the stability of the process on a layer-by-layer basis, and to detect the onset of defects as soon as possible. On the one hand, AM systems must be equipped with in-situ sensing devices able to measure relevant quantities during the process, a.k.a. process signatures. On the other hand, in-process data analytics and statistical monitoring techniques are required to detect and localize the defects in an automated way. This paper reviews the literature and the commercial tools for insitu monitoring of Powder Bed Fusion (PBF) processes. It explores the different categories of defects and their main causes, the most relevant process signatures and the in-situ sensing approaches proposed so far. Particular attention is devoted to the development of automated defect detection rules and the study of process control strategies, which represent two critical fields for the development of future smart PBF systems.
505 citations
Cites background or methods from "Review of in-situ process monitorin..."
...To face this issue, the development of process monitoring methodologies based on insitu sensing as well as novel feedback control strategies was indicated as a priority research area by many recent keynote studies, projects and roadmaps (Mellor et al., 2014; Olakanmi et al., 2015; Mani et al., 2015; Tapia and Elwany, 2014; Everton et al., 2016; Spear and Gold, 2016; Todorov et al., 2014)....
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...…as well as novel feedback control strategies was indicated as a priority research area by many recent keynote studies, projects and roadmaps (Mellor et al., 2014; Olakanmi et al., 2015; Mani et al., 2015; Tapia and Elwany, 2014; Everton et al., 2016; Spear and Gold, 2016; Todorov et al., 2014)....
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...In addition, Tapia and Elwany (2014), Mani et al. (2015), Spears and Gold (2016) and Everton et al. (2016) presented a review of in-situ sensing and monitoring methods proposed in the literature....
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...Nevertheless, the lack of process robustness, stability and repeatability was pointed out to be a major barrier for the industrial breakthrough of metal AM systems (Mani et al., 2015; Tapia and Elwany, 2014; Everton et al., 2016; Spear and Gold, 2016; Sharratt, 2015; Sames et al., 2016)....
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06 Apr 2016
TL;DR: Marshall has unique expertise in leveraging new digital tools, 3D printing, and other advanced manufacturing technologies and applying them to propulsion systems design and other aerospace materials to meet NASA mission and industry needs.
Abstract: Propulsion system development requires new, more affordable manufacturing techniques and technologies in a constrained budget environment, while future in-space applications will require in-space manufacturing and assembly of parts and systems. Marshall is advancing cuttingedge commercial capabilities in additive and digital manufacturing and applying them to aerospace challenges. The Center is developing the standards by which new manufacturing processes and parts will be tested and qualified. Rapidly evolving digital tools, such as additive manufacturing, are the leading edge of a revolution in the design and manufacture of space systems that enables rapid prototyping and reduces production times. Marshall has unique expertise in leveraging new digital tools, 3D printing, and other advanced manufacturing technologies and applying them to propulsion systems design and other aerospace materials to meet NASA mission and industry needs. Marshall is helping establish the standards and qualifications “from art to part” for the use of these advanced techniques and the parts produced using them in aerospace or elsewhere in the U.S. industrial base.
481 citations
References
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TL;DR: The state-of-the-art of additive manufacturing (AM) can be classified into three categories: direct digital manufacturing, free-form fabrication, or 3D printing as discussed by the authors.
Abstract: This paper reviews the state-of-the-art of an important, rapidly emerging, manufacturing technology that is alternatively called additive manufacturing (AM), direct digital manufacturing, free form fabrication, or 3D printing, etc. A broad contextual overview of metallic AM is provided. AM has the potential to revolutionize the global parts manufacturing and logistics landscape. It enables distributed manufacturing and the productions of parts-on-demand while offering the potential to reduce cost, energy consumption, and carbon footprint. This paper explores the material science, processes, and business consideration associated with achieving these performance gains. It is concluded that a paradigm shift is required in order to fully exploit AM potential.
4,055 citations
"Review of in-situ process monitorin..." refers background in this paper
...In addition, key reviews have been published in the area of applications and opportunities for AM techniques; these have centred around biomedical [6,7] aerospace [8], tooling [9] and general manufacturing [10]....
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Book•
01 Jan 2009
TL;DR: Gibson et al. as discussed by the authors presented a comprehensive overview of additive manufacturing technologies plus descriptions of support technologies like software systems and post-processing approaches, and provided systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing.
Abstract: Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing deals with various aspects of joining materials to form parts. Additive Manufacturing (AM) is an automated technique for direct conversion of 3D CAD data into physical objects using a variety of approaches. Manufacturers have been using these technologies in order to reduce development cycle times and get their products to the market quicker, more cost effectively, and with added value due to the incorporation of customizable features. Realizing the potential of AM applications, a large number of processes have been developed allowing the use of various materials ranging from plastics to metals for product development. Authors Ian Gibson, David W. Rosen and Brent Stucker explain these issues, as well as: Providing a comprehensive overview of AM technologies plus descriptions of support technologies like software systems and post-processing approaches Discussing the wide variety of new and emerging applications like micro-scale AM, medical applications, direct write electronics and Direct Digital Manufacturing of end-use components Introducing systematic solutions for process selection and design for AM Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing is the perfect book for researchers, students, practicing engineers, entrepreneurs, and manufacturing industry professionals interested in additive manufacturing.
3,087 citations
TL;DR: In this article, the development of the microstructure of the Ti-6Al-4V alloy processed by selective laser melting (SLM) was studied by light optical microscopy.
2,201 citations
"Review of in-situ process monitorin..." refers background in this paper
...[33,36] Entrapped gas pores within the bulk of...
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...Awide range ofmaterial discontinuities are known to occur during AM processing, the most common of which (termed pores) are voids that are situated in the bulk of the fused material either in between layers (elongated pores [33]) or within the layer (gas pores [34])....
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...[33,36,43] Lack of fusion pores in between layers...
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TL;DR: In this paper, a simple theoretical model is developed to predict residual stress distributions in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this phenomenon.
Abstract: Purpose – This paper presents an investigation into residual stresses in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this phenomenon.Design/methodology/approach – First, the origin of residual stresses is explored and a simple theoretical model is developed to predict residual stress distributions. Next, experimental methods are used to measure the residual stress profiles in a set of test samples produced with different process parameters.Findings – Residual stresses are found to be very large in SLM parts. In general, the residual stress profile consists of two zones of large tensile stresses at the top and bottom of the part, and a large zone of intermediate compressive stress in between. The most important parameters determining the magnitude and shape of the residual stress profiles are the material properties, the sample and substrate height, the laser scanning strategy and the heating conditions.Research limitations/implications – All exper...
1,415 citations
"Review of in-situ process monitorin..." refers background in this paper
...[40,48] Cracks can be within the component o...
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...Residual stresses have also been observed in laser-PBF components; the chosen hatching regime plays a major role in the residual stress development of a part, with resulting stresses concentrated perpendicular to the scan direction [40]....
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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