Skip to main content
SpringerLink
Log in

A novel high-efficiency methodology for metal additive manufacturing

  • Published:
Applied Physics A Aims and scope Submit manuscript

Abstract

Metal additive manufacturing (AM) offers unrivalled design freedom with the ability to manufacture complex parts. However, the high capital costs and slow throughput printing have severely restricted its application. In this paper, a new metal AM process, referred to as the “metal fused-coating additive manufacturing (MFCAM)”, was developed for highly efficient metal parts production. This new process is the combination of metal fused-coating process and laser surface melting process. A two-dimensional numerical model was established to provide an insight into the primary thermo-physical phenomena occurring in the MFCAM process. Experiments of single-track formation were conducted using MFCAM to validate the feasibility of the proposed process. The good agreement between experimental and simulated results demonstrated the reasonableness of the established models.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. ASTM F2792-12a, http://www.astm.org/Standards/F2792.htm (2015)

  2. J.J. Beaman, C.R. Deckard, Selective laser sintering with assisted powder handling. US Patent No. 4938816 (1990)

  3. J. Warton, R. Dwivedi, R. Kovacevic, Additive manufacturing of metallic alloys, in Robotic Fabrication in Architecture, Art and Design 2014, ed. by W. McGee, M. Ponce de Leon (Springer, Berlin, 2014), pp. 147–161

    Chapter  Google Scholar 

  4. D. Herzog, V. Seyda, E. Wycisk, C. Emmelmann, Additive manufacturing of metals. Acta Mater. 117(15), 371–392 (2006)

    Google Scholar 

  5. SLM Solutions GmbH, www.slm-solutions.com

  6. EOS Electro Optical Systems GmbH, www.eos.info

  7. Concept Laser GmbH, www.concept-laser.com

  8. Trumpf GmbH & Co. KG, www.trumpf.com

  9. DM3D Technology, LLC, www.pomgroup.com

  10. Sandia National Laboratories, www.sandia.gov

  11. E.C. Santos, M. Shiomi, K. Osakada, T. Laoui, Rapid manufacturing of metal components by laser forming. Int. J. Mach. Tool. Manuf. 46(12), 1459–1468 (2006)

    Article  Google Scholar 

  12. P. Wanjara, M. Brochu, M. Jahazi, Electron beam freeforming of stainless steel using solid wire feed. Mater. Des. 28(8), 2278–2286 (2007)

    Article  Google Scholar 

  13. T. Scharowsky, F. Osmanlic, R.F. Singer, C. Körner, Melt pool dynamics during selective electron beam melting. Appl. Phys. A Mater. 114(4), 1303–1307 (2014)

    Article  ADS  Google Scholar 

  14. B. Baufeld, O. Van der Biest, R. Gault, Additive manufacturing of Ti–6Al–4V components by shaped metal deposition: microstructure and mechanical properties. Mater. Des. 31, S106–S111 (2010)

    Article  Google Scholar 

  15. G.C. Anzalone, Z. Chenlong, B. Wijnen, P.G. Sanders, J.M. Pearce, A low-cost open-source metal 3-D printer. IEEE Access 1, 803–810 (2013)

    Article  Google Scholar 

  16. M. Baumers, P. Dickens, C. Tuck, R. Hague, The cost of additive manufacturing: machine productivity, economies of scale and technology-push. Technol. Forecast. Soc. Change 102, 193–201 (2016)

    Article  Google Scholar 

  17. M. Orme, A novel technique of rapid solidification net- form materials synthesis. J. Mater. Eng. Perform. 2(3), 399–405 (1993)

    Article  Google Scholar 

  18. J. Du, Z. Wei, Numerical analysis of pileup process in metal microdroplet deposition manufacture. Int. J. Therm. Sci. 96, 35–44 (2015)

    Article  Google Scholar 

  19. J. Luo, L.-H. Qi, X.-S. Jiang, J.-M. Zhou, H. Huang, Research on lateral instability of the uniform-charged droplet stream during droplet-based freeform fabrication. Int. J. Mach. Tool. Manuf. 48(3–4), 289–294 (2008)

    Article  Google Scholar 

  20. X. Luo, Z. Li, G. Chen, W. Xu, Q. Yan, Effect of substrate movement speed by synchronous rolling-casting freeform manufacturing for metal on microstructure and mechanical property of ZL104 aluminum alloy slurry. J. Wuhan Univ. Technol. Mater. Sci. 30(5), 1056–1060 (2015)

    Article  Google Scholar 

  21. M. Mughal, H. Fawad, R. Mufti, Three-dimensional finite-element modelling of deformation in weld-based rapid prototyping. Proc. Inst. Mech. Eng. C J. Mech. Eng. Sci. 220(6), 875–885 (2006)

    Article  MATH  Google Scholar 

  22. R.J. Silva, G.F. Barbosa, J. Carvalho, Additive manufacturing of metal parts by welding, in 15th IFAC Symposium onInformation Control Problems in Manufacturing—INCOM 2015, Ottawa, Canada, vol. 48 (2015), pp. 2318–2322

  23. C.W. Hirt, B.D. Nichols, Volume of fluid (VOF) method for the dynamics of free boundaries. J. Comput. Phys. 39(1), 201–225 (1981)

    Article  ADS  MATH  Google Scholar 

  24. J. Goldak, A. Chakravarti, M. Bibby, A new finite element model for welding heat sources. Metall. Mater. Trans. B 15(2), 299–305 (1984)

    Article  ADS  Google Scholar 

  25. G. Fu, J. Gu, M.I. Lourenco, M. Duan, S.F. Estefen, Parameter determination of double-ellipsoidal heat source model and its application in the multi-pass welding process. Ships Offshore Struct. 10(2), 204–217 (2015)

    Article  Google Scholar 

Download references

Acknowledgments

The research is financially supported by National Natural Science Foundation of China under Grant No. 31370944 and the Fundamental Research Funds for the Central Universities.

Author information

Authors and Affiliations

  1. State Key Laboratory of Manufacturing System Engineering, Xi’an Jiaotong University, Xi’an, 710049, China

    Jun Du, Zhengying Wei, Xin Wang, Xuewei Fang & Guangxi Zhao

Authors
  1. Jun Du
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhengying Wei
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Xin Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Xuewei Fang
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Guangxi Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jun Du.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Du, J., Wei, Z., Wang, X. et al. A novel high-efficiency methodology for metal additive manufacturing. Appl. Phys. A 122, 945 (2016). https://doi.org/10.1007/s00339-016-0480-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s00339-016-0480-2

Keywords

Search

Navigation