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A state-of-the-art review on energy consumption and quality characteristics in metal additive manufacturing processes

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Abstract

This paper aims to study the energy consumption and quality characteristics of the parts fabricated by additive manufacturing (AM) technologies with a special focus on metal AM processes. AM is a family of manufacturing techniques, which is broadly used to fabricate complex and lightweight structures. The energy savings during AM processes have a significant influence on the AM industry, only if the quality of the fabricated part meets the requirements. The quality is generally represented by the surface and dimensional quality, mechanical properties, relative density, hardness, etc. The energy saving is important for environmentally benign and cleaner production, and improved product quality is useful for its application as a functional part in the aerospace, automobile, and biomedical industries. A comprehensive review of the energy consumption and quality characteristics of AM-fabricated (with special focus on metal AM) parts was carried out. Firstly, the specific energy consumption of various AM techniques has been reviewed to address the importance of energy and cleaner production. Then, the qualifications of products fabricated by different metal AM techniques have been discussed for different materials, such as titanium alloys, steel alloys, nickel alloys, and aluminum alloys. Also, by considering the practical importance of thin-walled structures fabricated by AM, a detailed analysis of their qualification has been presented. Moreover, different optimization techniques have also been reviewed for various AM process parameters and objectives. Overall, this paper provides an overview of AM, including a survey on the energy consumption and quality characteristics with the development of AM technologies for manufacturing of quality products. Finally, several future research directions are suggested, specifically the need for a framework for metal AM processes for the fabrication of quality products with minimum energy consumption.

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Abbreviations

3D:

Three-dimensional

3DP:

3D Printing

AM:

Additive manufacturing

ASTM:

American society of testing and materials

BJP:

Binder jet printing

CM:

Conventional manufacturing/machining

CNC:

Computer numerically controlled

CNTs:

Carbon nanotubes

DLD:

Direct laser deposition

DLF:

Direct laser forming

DLS:

Direct laser sintering

DMD:

Direct metal deposition

DMLS:

Direct metal laser sintering

DoE:

Design of experiments

EBM:

Electron beam melting

FDM:

Fused deposition modeling

GA:

Genetic algorithm

IM:

Injection molding

LENS:

Laser-engineered net shaping

LOM:

Laminated object manufacture

MO:

Multi-objective

NSGA-II:

Non-dominated sorting genetic algorithm-II

PBF:

Powder bed fusion

RP:

Rapid prototyping

SAM:

Sustainability of additive manufacturing

SEC:

Specific energy consumption

SEM:

Spectroelectron microscopy

SL/SLA:

Stereolithography

SLM:

Selective laser melting

SLS:

Selective laser sintering

SS:

Stainless steel

STL:

Stereolithography file

TEC:

Total energy consumption

UAM:

Ultrasonic additive manufacturing

WAAM:

Wire and arc additive manufacturing

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Acknowledgements

This research is supported by the National Natural Science Foundation of China (No. 51505423, 51705428), Natural Science Basic Research Plan in Shaanxi Province of China (No. 2020JQ-380), and Natural Science Foundation of Zhejiang Province (No. LY19E050019).

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Authors and Affiliations

  1. Key Laboratory of Industrial Engineering and Intelligent Manufacturing, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Arfan Majeed & Muhammad Muzamil

  2. Department of Management Science & Engineering, School of Economics and Management, Beihang University, Beijing, 100191, China

    Altaf Ahmed

  3. Key Laboratory of Road Construction Technology and Equipment, Ministry of Education, School of Construction Machinery, Chang’an University, Xi’an, 710064, Shaanxi, China

    Jingxiang Lv

  4. Key Laboratory of 3D Printing Process and Equipment of Zhejiang Province, Institute of Industrial Engineering, School of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China

    Tao Peng

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  1. Arfan Majeed
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Correspondence to Arfan Majeed or Jingxiang Lv.

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Majeed, A., Ahmed, A., Lv, J. et al. A state-of-the-art review on energy consumption and quality characteristics in metal additive manufacturing processes. J Braz. Soc. Mech. Sci. Eng. 42, 249 (2020). https://doi.org/10.1007/s40430-020-02323-4

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