Metal Additive Manufacturing Conference - MAMC 2023

Ti-6-4 processed by L-PBF (Laser Powder Bed Fusion) is known to have an anisotropic microstructure due to the unidirectional build process, which leads to anisotropic ductility and fatigue behavior. Boron is known to be a nucleation starter within Titanium alloys, leading to a refinement in the microstructure. Within this work, the effects of in-situ alloying of Ti6Al4V and B on the...

Laser Powder Bed Fusion (L-PBF) is a 3D printing technology that has gained worldwide acceptance due to its high resolution and accuracy. However, high equipment and material costs, residual stresses in the manufactured parts and internal defects are still major barriers to widespread industrial use. Preheating is a process in which the powder bed is heated during the production run. This...

The processing by Laser powder bed fusion of non-weldable gamma’-strengthened Ni-based superalloys is recognized as challenging, especially due to hot cracking and liquation cracking mechanisms that occur during the solidification and the early cooling stages of the alloys.
The current study, which is based on activities carried out within the Horizon 2020 joint research project CUSTODIAN...

Ti-5Al-5V-5Mo-3Cr or Ti-5553 is a metastable β Titanium alloy with excellent mechanical properties. Compared to the most common titanium alloy, the α and β Ti6Al4V, it offers improved tensile and fatigue strength while highly tunable by heat treatment.
In scope of this work, the processability of T-5553 by Laser powder bed fusion (L-PBF) is investigated. The possible advantages of metastable...

Additive manufacturing using wire arc technology, especially Cold Metal Transfer
(CMT), has become increasingly popular in the generation of large-scale and complex
shaped 3D parts. However, heat input and solidification shrinkage during deposition
causes distortions and residual stresses. These can significantly affect the geometric
accuracy and mechanical properties of the deposit....

Wire-based DED/LMD promises some unique advantages compared to powder-based DED. Most relevant are the low cost of the starting material and the reduced health and safety risks. In the recent years, wire DED was mainly used for R&D purposes. In this study, however, we will present the adoption of wire DED to industrial requirements using Inconel 625 and 718 materials. By optimizing the system...

Wire-DED Plasma Arc (W-DED-PArc) has emerged as a promising Additive Manufacturing technology ‎for fabricating high-performance and large-volume metal parts. However, producing multi-material ‎components remains one of the challenges due to the interfacial properties, intermetallic phases, and ‎compatibility of the different alloys to be joined together. The current study investigated the...

Wire-based directed energy deposition (w-DED) is a sophisticated technology for producing structural components. Managing bead features and defining process parameters are critical parts of the w-DED process for producing a flawless final product with minimal material waste. Based on thermo-physical relations, a thermo-capillary-gravity bidirectional model has been devised in this study for...

A notable limitation in current commercial laser powder bed fusion (LPBF) systems emanates from the non-uniform thermal conditions caused by conventional laser beams. The utilization of Gaussian intensity patterns in existing setups gives rise to significant issues, including excessive overheating and material evaporation, stemming from the concentration of energy at the central beam point....

Microstructures of single layer AISI M4 high speed steel deposited on AISI D2 tool steel substrate using L-DED process with two levels of global energy density were characterized and compared.
A five-axes PRECO-SL 8600 CNC machine was used to deposit the M4 powder feedstock with a continuous wave laser source, near-infrared wavelength laser beam, 2.0 mm spot size and coaxial continuous feed...

Wire and Arc Additive Manufacturing (WAAM) is a metal 3d printing process suitable for building large, semi-complex, near-net shape components. The Welding and Additive Manufacturing Centre at Cranfield University has been at the forefront of WAAM development, working on this technology for over 17 years, investigating processes, materials, and the manufacture of components. WAAM can replace...

Reduced and real-time modelling is one of the main pillars of digital “process models” for twining of manufacturing processes. Starting from the data processing and model building, a digital twin of additive manufacturing (AM) processes involves creating virtual replica where predictions and corrections can be made in real-time. Developing such fast predictive/corrective digital models involve...