| 1. |
- Ahmed, N., et al.
(författare)
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Process parameter selection and optimization of laser powder bed fusion for 316L stainless steel : A review
- 2022
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Ingår i: JOURNAL OF MANUFACTURING PROCESSES. - : Elsevier BV. - 1526-6125. ; 75, s. 415-434
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Forskningsöversikt (refereegranskat)abstract
- Stainless steel 316L has been an extensively investigated metallic material for laser powder bed fusion (L-PBF) in the past few decades due to its high corrosion resistance. However, there are challenges related to producing LPBF parts with minimal defects, attaining mechanical properties comparable with traditional process and dependency on time consuming post process treatments. The selection of L-PBF process parameters is crucial to overcome these challenges. This paper reviews the research carried out on L-PBF process parameter optimization for fabrication of 316L steel components for maximizing part densifications and attaining desired microstructure morphologies in parts. A brief work on numerical simulation approach for process parameter optimization for high densifications is also included in this paper.
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| 2. |
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| 3. |
- Bournias-Varotsis, Alkaios, et al.
(författare)
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Ultrasonic Additive Manufacturing as a form-then-bond process for embedding electronic circuitry into a metal matrix
- 2018
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Ingår i: Journal of Manufacturing Processes. - London : Elsevier. - 1526-6125. ; 32, s. 664-675
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Tidskriftsartikel (refereegranskat)abstract
- Ultrasonic Additive Manufacturing (UAM) is a hybrid manufacturing process that involves the layer-by-layer ultrasonic welding of metal foils in the solid state with periodic CNC machining to achieve the desired 3D shape. UAM enables the fabrication of metal smart structures, because it allows the embedding of various components into the metal matrix, due to the high degree of plastic metal flow and the relatively low temperatures encountered during the layer bonding process. To further the embedding capabilities of UAM, in this paper we examine the ultrasonic welding of aluminium foils with features machined prior to bonding. These pre-machined features can be stacked layer-by-layer to create pockets for the accommodation of fragile components, such as electronic circuitry, prior to encapsulation. This manufacturing approach transforms UAM into a “form-then-bond” process. By studying the deformation of aluminium foils during UAM, a statistical model was developed that allowed the prediction of the final location, dimensions and tolerances of pre-machined features for a set of UAM process parameters. The predictive power of the model was demonstrated by designing a cavity to accommodate an electronic component (i.e. a surface mount resistor) prior to its encapsulation within the metal matrix. We also further emphasised the importance of the tensioning force in the UAM process. The current work paves the way for the creation of a novel system for the fabrication of three-dimensional electronic circuits embedded into an additively manufactured complex metal composite. © 2018 The Society of Manufacturing Engineers
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| 4. |
- Broqvist, Natalia, et al.
(författare)
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On wear resistance of tool steel
- 2012
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Ingår i: Journal of Manufacturing Processes. - : Elsevier BV. - 1526-6125. ; 14:3, s. 195-198
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Tidskriftsartikel (refereegranskat)abstract
- Maintaining a reasonably low cutting tool wear when producing forming tools is a general challenge in the development of new forming tool materials. The tool life of a hot forming tool steel (H13) has been significantly improved by reducing its Si-content from 1.0 to 0.06 wt.%. However, this modified H13 (MH13) also displays a reduced cutting tool life due to higher cutting forces and a stronger tendency to form built up layers (BUE) on the cutting edge. This paper explains why.Gleeble tests of MH13 revealed a significantly higher flow stress in the 820–900 °C temperature interval in MH13 compared to H13. Thermo-Calc simulations showed that when reducing the Si-content from 1.0 to 0.06 wt.% the initial temperature for ferrite-to-austenite transformation (A1) was reduced from 900 °C to 820 °C. Knowing that austenite has totally different mechanical and thermal properties than ferrite, the difference in A1 between the two steels explains the higher cutting forces and higher tendency for BUE-formation. The conclusion is that the difference in machinability between H13 and MH13 is primarily related to their difference in A1.An attempt was also made to find a new tool material composition that can combine the wear resistance of MH13 and the good machinability of H13. Thermo-Calc simulations were performed with slightly modified alloying content without changing its properties as a good forming tool material, with the aim to increase A1. For instance, reducing the Mn content from 0.5 to 0.05 wt.% proved to increase A1 from 820 to 850 °C.
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| 5. |
- Bunaziv, Ivan, et al.
(författare)
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Filler metal distribution and processing stability in laser-arc hybrid welding of thick HSLA steel
- 2020
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Ingår i: Journal of Manufacturing Processes. - : Elsevier. - 1526-6125. ; 54, s. 228-239
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Tidskriftsartikel (refereegranskat)abstract
- Welds made by high power laser beam have deep and narrow geometry. Addition of filler wire by the arc source, forming the laser-arc hybrid welding (LAHW) process, is very important to obtain required mechanical properties. Distribution of molten wire throughout the entire weld depth is of concern since it tends to have low transportation ability to the root. Accurate identification of filler metal distribution is very challenging. Metal-cored wires can provide high density of non-metallic inclusions (NMIs) which are important for acicular ferrite nucleation. Accurate filler distribution can be recognized based on statistical characterization of NMIs in the weld. In the present study, it was found that the amount of filler metal decreased linearly towards the root. The filler metal tends to accumulate in the upper part of the weld and has a steep decrease at 45–55 % depth which also has wavy pattern based on longitudinal cuts. Substantial hardness variation in longitudinal direction was observed, where in the root values can reach > 300 HV. Excessive porosity was generated at 75 % depth due to unstable and turbulent melt flow based on morphology of prior austenite grains. The delicate balance of process parameters is important factor for both process stability and filler metal distribution.
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| 6. |
- Chen, Zhuoer, 1989, et al.
(författare)
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Influence of part geometry on spatter formation in laser powder bed fusion of Inconel 718 alloy revealed by optical tomography
- 2022
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Ingår i: Journal of Manufacturing Processes. - : Elsevier BV. - 1526-6125. ; 81, s. 680-695
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Tidskriftsartikel (refereegranskat)abstract
- The metal powder used during the Laser Powder Bed Fusion (L-PBF) process is usually cycled for reuse in subsequent build jobs for cost-effectiveness and sustainability. Qualification guidelines are being established based on testing results of powder properties in terms of flowability, chemistry and rheological behaviors, etc. for making decisions on whether a batch of reused powder is suitable for producing parts that meet certain requirements. The current paper aims to develop experimental strategies for tracking powder history using novel design of specimens and on-line monitoring. Powder-capturing containers designed with internal lattice structures of varied beam lengths and diameters were manufactured by the L-PBF process using an Inconel 718 powder to investigate the influence of part geometry on the degradation of reused powder. The L-PBF experiment was monitored by a commercial Optical Tomography (OT) system which records the thermal emissions from the build area. Data were extracted from the OT images to evaluate the emissions of spatter particles introduced to the powder bed, which is influenced by the local layer profiles of the lattices and the overall geometries of the container. The collected powder samples were tested by combustion analysis for oxygen content and characterized by Scanning Electron Microscopy (SEM). Surface chemistry analyses of the powders were performed by X-ray Photoelectron Spectroscopy (XPS). Depending on the lattice structure geometry, the oxygen uptake in the powder collected from the containers was increasing by 10 ppm in case of empty container and up to as high as 118 ppm in case of container with larger areas of overhangs and higher surface-to-volume ratio. XPS results revealed the presences of Al-rich and Cr-rich oxides on the surface of powder samples collected from the container filled with lattices of high surface-to-volume ratio and the container filled with lattices of large overhangs, which agrees with the analyses of OT data.
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| 7. |
- Chen, Zhan, et al.
(författare)
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Iteration based calculation of position and orientation of grinding wheel for solid cutting tool flute grinding
- 2018
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Ingår i: JOURNAL OF MANUFACTURING PROCESSES. - : ELSEVIER SCI LTD. - 1526-6125. ; 36, s. 209-215
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Tidskriftsartikel (refereegranskat)abstract
- End mill cutting tools are widely used in machining of curved surface parts in many areas, e.g. aerospace, automobile, and energy. The parameters of helical groove cross section, influencing chip removal capacity, include rake angle, core radius and edge width. Towards a parametrical control algorithm of the cutting tool flute, this paper proposed an iteration based method. Within the context, the cutting tool parameters and grinding wheel are set firstly. Then, three angle parameters, alpha, beta, and theta in the grinding coordinate system, are looped. In each loop, one of the target flute parameters is compared with the pre-set values, and if the parameter is within the range, the calculation goes the next loop until the parameters are in the target range. Since the loop number is so high that the computing time is too long, the patterns between the flute parameters and looped parameters are used to improve the calculation speed. The method is implemented by using C#, and validated by a set of numeric simulation based on Matlab (R).
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| 8. |
- Da Silva, Adrien, et al.
(författare)
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Melt pool monitoring and process optimisation of directed energy deposition via coaxial thermal imaging
- 2023
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Ingår i: Journal of Manufacturing Processes. - : Elsevier. - 1526-6125. ; 107, s. 126-133
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Tidskriftsartikel (refereegranskat)abstract
- In Laser-based Directed Energy Deposition of metal powder, the use of optimised parameters allows the deposition of defect-free material, while diverging from these optimised parameters can typically result in high porosity, high dilution or different track geometry. One of the main challenges when building complex geometries is that the geometrical and thermal conditions of the deposition are constantly changing, which requires to adjust the process parameters during the production. In order to facilitate this process, sensors such as thermal cameras can be used to extract data from the process and adapt the parameters to keep the process stable despite external disturbances. In this research, different signals extracted from a coaxial thermal camera are investigated and compared for process optimisation. To investigate such possibilities, five overlapped tracks are deposited at constant laser powers in order to extract average pixel values as well as the melt pool area, length, width and orientation. The behaviour of each track deposition is modelled as a function of the laser power, and these models are used to calculate and test laser power reduction strategies based on different signals. The results show that the melt pool area is the most relevant signal to use for an efficient process control, resulting in a stable process with only ±1.6 % of signal variation from track to track.
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| 9. |
- de Andrade Schwerz, Claudia, 1992, et al.
(författare)
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Increasing productivity of laser powder bed fusion manufactured Hastelloy X through modification of process parameters
- 2022
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Ingår i: Journal of Manufacturing Processes. - : Elsevier BV. - 1526-6125. ; 78, s. 231-241
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Tidskriftsartikel (refereegranskat)abstract
- One of the factors limiting the use of additive manufacturing, particularly powder bed processes, is their low productivity. An approach to increasing laser powder bed fusion (LPBF) build rate without costly hardware modifications is to alter process parameters. This study evaluates the possibilities to increase build rates through this route without compromising material quality. Equations for productivity are derived based on process parameters and build geometry, and applied on the process window for Hastelloy X in LPBF. It is demonstrated that virtually flaw-free parts can be printed at build rates that differ up to tenfold. To investigate potential variations in the microstructure and performance, Hastelloy X specimens manufactured at varying build rates were characterized. Electron backscattered diffraction (EBSD) analysis revealed that the specimen built at the lowest rate shows strong texture with columnar grains, while the specimen built at the highest rate presents significantly more random orientation and evident melt pool contours with pockets of very fine grains at the bottom. Despite the major differences in microstructure, the tensile properties do not necessarily vary substantially. Thus, the results indicate that the build rate of LPBF Hastelloy X can be significantly varied based on process parameters, still yielding consistent mechanical properties.
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| 10. |
- Deckers, Tobias, et al.
(författare)
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Impact of processing gas composition on process stability and properties of PBF-LB/M processed alloy 718
- 2024
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Ingår i: Journal of Manufacturing Processes. - 1526-6125. ; 120, s. 712-718
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Tidskriftsartikel (refereegranskat)abstract
- The almost unlimited design freedom of the laser-based powder bed fusion of metals (PBF-LB/M) makes this technology very attractive for industry. However, as a developing technology, it still faces some challenges when it comes to productivity and robustness, to name some. Whereas numerous studies covered the impact of laser-based parameters on material properties and robustness, the effect of the processing gas received limited attention. The objective of this study was to evaluate the effect of processing gas composition, containing helium (He) and hydrogen (H2), compared to conventionally used argon (Ar), during PBF-LB/M processing of virgin alloy 718 powder, on printing behavior and part properties. The four gases studied were Ar, Ar +30%He, Ar +30%He +2%H2, and Ar +70%He. Optical Tomography (OT) was used to monitor process stability, which unveiled a significant decrease in process-by products (spatters) between 51 % and 89 % using He and H2-containing gases. It was also found that the process gas decreased the bulk porosity from an average value of 0.08 % when processed with Ar to 0.04 % when using Ar + 70%He. The oxygen pickup by the spatter particles was reduced from 630 ppm (Ar) to 331 ppm (Ar +70%He). EBSD analysis revealed that there were no evident changes in microstructure with the processing gas. The samples processed also had similar tensile properties with yield and ultimate tensile strength of 1180 MPa and 1395 MPa, respectively. However, there was a slight increase in ductility from 16.5 % to 17.2 %, when processed with pure Ar and Ar + 70%He, respectively. This study shows that utilizing standard Ar processing atmosphere with He addition leads to a more stable process with reduced spatter, porosity and a marginal increase in ductility for Alloy 718.
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