Metal Additive Manufacturing Conference - MAMC 2024

The speech will also focus on the production of Metal Powders and Powder Metallurgical Steels and especially its associated production technologies like HIP, MIM and AM. As they are and will become key future core technologies for a number of demanding products and thus for the usage in different associated industries. The presentation will also highlight the actual supply and demand situation...

Additive manufacturing has made significant progress in recent years, particularly with the advent of next-generation technologies. This lecture explores cutting-edge innovations that are reshaping the Additive Manufacturing landscape and propelling it into a new frontier. The focus is on innovative AM processes, including the state-of-the-art of processing of metallic materials such as Ti-,...

Additive Manufacturing technologies are growing rapidly and moving towards industrial-grade production technology; however the development and qualification of materials and processes remain time-consumingand costly challenges for faster AM adoption. An integrated multi-scale approach designed to accelerate AM materials and process development and qualification will be discussed as a potential...

The different technologies in Metal Additive Manufacturing evolved to a technology and manufacturing readiness to apply them in serial production of functional as well as critical parts. Still industrialization in datamanagement, automation and lean production is ongoing to enable a stronger penetration in the manufacturing sector. An overview with production examples is given on the progress...

Abstract

This work investigates the corrosion morphology of AISI 316L stainless steel produced by laser powder bed fusion (L-PBF). The behavior of the as printed surface is compared with that of the bulk material to understand the effect of microstructure and roughness of the as printed surface on its corrosion behavior.
The L-PBF specimens investigated in this work were manufactured with...

The limitations of existing additive manufacturing processes often include long printing times and time-consuming post-processing steps due to the removal of components from a powder bed or the removal of support structures.
The MoldJet® process developed by Tritone® Technologies Ltd. is a sinter-based additive manufacturing process that is equally suitable for the productive fabrication of...

The 3D Master method aims to reduce effort and misinterpretation while transferring product information from the design office to the production department, thanks to 3D model files containing all the product manufacturing information (PMI).
Thus, for a metal additive manufacturing (MAM) part, the 3D Master method gives direct access to crucial data, such as the product’s materials and 3D...

Laser Powder Bed Fusion (LPBF) remains a predominant process in the additive manufacturing for metals, and is widely adopted by equipment manufacturers, within research circles, and across a spectrum of industrial applications. Despite its prominence, LPBF faces inherent limitations regarding the complexity of geometries it can produce, the diversity of processable materials, and its overall...

The advantages of the PBF-LB/M process, such as geometric complexity due to increased design freedom or function integration, offer great potential for optimizing products in the automotive sector. However, it often does not go beyond prototyping and small series, as productivity is too low for the required quantities and economies of scale can rarely be exploited lucratively. In the field of...

Additive manufacturing technology has initiated a transformative phase in the industrial landscape, particularly in the realm of metal 3D printing. A key element for the success of this revolutionary manufacturing method lies in the availability of high-quality metal powders that meet the specific requirements of various applications. This work sheds light on the innovative development of new...

This study investigates the utilization of machine learning for optimizing additive manufacturing processes, focusing on Laser PowderBed Fusion (L-PBF) and Laser Metal Deposition (LMD). By leveraging domain expertise, machine learning demonstrates significant potential in enhancing efficiency and quality. Through specific case studies, we highlight the benefits and limitations of...

The heat evolution and thereby the densification rate in Laser Powder Bed Fusion (LPBF) Metal 3D Printing may vary during the print depending upon the build geometry variation along the height. Such variations in densification, even at fixed print parameters, are a major cause of defective parts in metal AM, as well as the poor consistency of print quality form part to part. We present a...

The development of new alloys for additive manufacturing, aiming at specific tailored properties, constitutes a topic of high interest.
• For instance, aluminum alloys are gaining significant attention in additive manufacturing, with numerous commercial alloys entering the market. However, most of these alloys primarily target Laser Powder Bed Fusion (L-PBF) applications i.e., they are...

Metal powders used in additive manufacturing (AM) are expensive and energy-intensive to manufacture desired engineering parts. Reusing these powders reduces material waste, lowers production costs, and minimizes the environmental footprint of AM processes to support sustainable manufacturing routes. Therefore, this study investigates the reusability/degradation of CX steel powders via laser...

A powder bed fusion – laser beam / metal (PBF-LB/M) process and hot isostatic pressing (HIP) combined producing route was developed to manufacture nitrogen (N) in high-alloyed stainless steels in which mechanically mixed base AISI stainless steel 304L (SS304L) powder and silicon nitride (Si3N4) powder was manufactured by PBF-LB/M and further homogenized by HIP. Due to the partially undissolved...

This study investigates the sustainable reuse of printed AlSi10Mg parts in metal Additive Manufacturing (AM) for Plasma Directed Energy Deposition (DED) processes, aiming to advance material circularity in the automotive industry. We focused on evaluating porosity on recycled AlSi10Mg specimens.

The research involved processing AlSi10Mg from used parts into powder for plasma DED,...

Weight reduction is crucial for transport industries (like aerospace), it is possible to achieve through topological optimization or by implementing lattice structures. This objective can be obtained by additive manufacturing processes. Besides, sustainability concerns are important and the use of upcycled powder feedstocks can be noteworthy. In the current study, we present an upcycling...

The development history of LPBF began 30 years ago at the Fraunhofer ILT in Aachen. LPBF is now the most important additive manufacturing process for metalliccomponents. This presentation will take a look back at the beginnings of the process and the key development steps, present the current technological and economic status and provide an insight into current development trends.

Additive manufacturing (AM), particularly Laser Powder Bed Fusion (LPBF), is rapidly advancing due to its increasing adoption as an advanced manufacturing technique capable of producing intricate and reliably consistent parts. However, this heightened interest in AM has prompted concerns regarding its sustainability. In response, a recent study conducted a comprehensive experimental effort...

This study explores the potential of 3D Plasma Metal Deposition (3DPMD), a directed energy deposition variant, for manufacturing components using aluminium powder. The work aims to understand the unique process-structure-properties relationships for 3DPMD with aluminium. The research involved conducting test series with single and multilayer deposits, giving insights into different aspects of...

Limitations in bulk metallic glass (BMG) additive manufacturing arise from the relaxation of solidified layers, diminishing free volume, and adversely affecting part quality. The first generation of freeform laser beam shaping technology has demonstrated its capacity to produce Zr-based BMG test coupons devoid of any detectable crystalline phases, thereby minimizing the reheating of preceding...

In the field of Laser-Based Directed Energy Deposition (DED-LB) processes, real-time process monitoring is a critical aspect that ensures the quality and integrity of the final product. While established methods exist for monitoring other process signatures such as molten pool size and temperature, the monitoring of the layer thickness presents a unique challenge, especially for processes...

Laser Powder Bed Fusion (L-PBF) technology offers the capability to manufacture a diverse range of components and features, which span from thin or hollow structures to massive elements. Typically, the primary parameters in the L-PBF process, such as laser power, scan speed, and hatching distance, are optimized for components with significant print areas, which can be divided into core and...

Remanufacturing is a comprehensive and rigorous industrial process by which a previously sold, leased, used, worn, remanufactured, or non-functional product or part is returned to a like-new, same-as-when-new, or better-than-when-new condition from both a quality and performance perspective, through a controlled, reproducible, and sustainable process. Remanufacturing is an archetype of a...

The landscape of LPBF process has evolved significantly during recent years, exceeding its origins in simple test production and prototyping towards manufacturing functional parts for real-world applications. Despite its potential, the current limitations in cost and efficiency of the process have held back the broader application of metal 3D printing. Various solutions have been proposed, yet...

Porous materials have always been a necessary component in application of catalysts, fuel cells or capacitors in the field of energy conversion and storage. They can be obtained by a variety of production methods, however a novel emerging method has been demonstrated by the use of additive manufacturing. With laser powder bed fusion (LPBF) several printing parameters, such as laser power,...

Molten Metal Deposition (MMD) represents an advanced wire-based aluminum additive manufacturing (AM) methodology wherein wire feedstock is directly liquified and extruded onto a heated substrate. This technique obviates the necessity for auxiliary energy sources such as lasers, as well as binders or additional support structures, thereby mitigating thermal stress implications and enhancing...

Laser powder bed fusion (L-PBF) has become a widely used process in the additive manufacturing of metals, for it combines the assets of a high degree of freedom in the design of parts with a high flexibility in the production process itself. In addition, material properties of L-PBF parts have been demonstrated to be able to equal or, in some cases, even exceed those of comparable, yet...

Towards the development of high-performance alloys with superior properties (strength and creep), dispersoid-strengthened (DS) alloys manufactured via additive manufacturing (AM) present a promising opportunity for design of high-performance components (e.g. gas burner heads). Challenges arise in alloys not designed for AM due to complex laser-material interactions. Hence, the integration of...

The energy sector uses a large amount of moving metallic parts, for example stainless steel pumps or collectors. Such kind of parts can be damaged during the use life and small cracks can appear after some years. Classically, the cracks are manually repaired with conventional welding techniques and the parts can still be used several years after the repair. However, the manual repair leads to...

Within the presentation an overlook of Aconity3D’s endeavor in providing the first closed-loop power laser control of the applied laser sourceswithin L-PBF is given. At this, current progress and limitations are provided, highlighting the state of the art in fully controlled first-time right approaches which forms a precondition for truly industrial manufacturing via Additive Manufacturing.

Powder Bed Fusion of Metals with Laser Beam (PBF-LB/M) is an additive manufacturing technology that creates parts layer by layer from metal powder. The scanning strategy, which defines the geometrical arrangement of laser scan vectors, influences the part quality. In this work, based on the literature, we identified efficiently assessable geometrical properties of scanning strategies as...

The surface finishing of complex metallic parts made by additive manufacturing, remains a challenge. Indeed, this kind of treatment is required to enhance the properties of the parts (cleanliness, mechanical properties, etc.) so that they are made compatible with their final use.

During this presentation, results of the FITFAME project (ESA GSTP GT1A-314MS), focusing on the finishing of...

Additive manufacturing processes are becoming increasingly popular. Metal Binder Jetting (MBJ) is emerging as a promising technique for high productivity in the simultaneous production of highly complex components. The limited number of materials available for MBJ creates a high potential for research. Especially in the field of nickel-free austenitic stainless steels, the choice of materials...

Fabrication of metal matrix composites with improved properties requires an understanding of how laser action interacts with ceramic fillers and metal matrices in laser powder bed fusion (LPBF) synthesis. This work investigates the dynamic behavior and chemical reactions that occur during LPBF synthesis when laser energy is applied to the interface between metal matrices and ceramic fillers....

Lightweight design is very closely associated with additive manufacturing. Besides the design possibilities offered by this technology, the material used also plays a key role. Especially in the LPBF process, the production of the powder and the processing of the material is a major challenge. This applies in particular to magnesium alloys as a lightweight material. Due to its low density and...

Additive manufacturing using wire arc technology 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. Process simulation offers the possibility to...

In the Laser Powder Bed Fusion (LPBF) process, metallic components are manufactured layer by layer by selectively melting metal powder using laser radiation. While the additive manufacturing principle allows parts ofalmost unlimited complexity to be produced, LPBF process control strategies are largely static according to the state of the art and only take into account the component geometry...

In this research, investigation is focused on Laser Powder Bed Fusion (L-PBF) of non-standard titanium-molybdenum-aluminium-vanadium alloys. The aim of the research is to develop additive manufacturing (AM) process parameters that can achieve full density of titanium alloys with different molybdenum contents with satisfactory static (tensile strength) and dynamic (fatigue behaviour) mechanical...

Binder jetting is ideal for producing individual parts with highly complex geometries. To achieve direct production of net-shape components with minimal post-processing, multi-scale numerical models were developed in this study to integrate the simulation of the manufacturing steps. Computational Fluid Dynamics (CFD) analysed the gas atomization process to calculate particle size distribution....

Additive manufacturing (AM) has a transformative potential when combined with advanced design strategies such as parametric and algorithmic design. This should be demonstrated on the application of hydrogen gas burners and be discussed on two key examples: the first involves the industrial application of a hydrogen burner designed for use in electric arc furnaces in the steel industry. The...

Forging tools endure extreme conditions, being subjected to both high temperatures and mechanical stresses on their operational surfaces. Enhancing resistance to external influences is crucial for extending their service life. This paper investigates the efficacy of incorporating a material layer, manufactured via Additive Manufacturing using Directed Energy Deposition (DED), to bolster the...

Laser Powder-Directed Energy Deposition (LP-DED) can be used to produce Functionally Gradient Materials (FGM) by gradually changing the composition fed into the melt pool. FGM components find many applications in various industrial fields as they are characterized by different functional performances along the part. The deposition of FGM components using AISI 316L/Inconel 718 via LP-DED is...

Additive Manufacturing (AM) has become increasingly popular in recent years due to its capability for rapid and on-demand production of parts, prototypes, and spare parts. It is often hailed as a “Green technology” due to lesser material usage compared to traditional manufacturing methods and possibilities for lightweighting the design. Many studies have focused on Life Cycle Assessments...

Additive manufacturing (AM) processes are gaining significant traction in various industries. The metal Binder Jetting (MBJ) process is particularly well-suited for high productivity and the production of highly complex components. However, the range of materials available for MBJ remains limited, presenting a substantial opportunity for further research. In particular, the use of powder...

The newest research for alternatives to autologous bone grafts when treating bone defects leads to the development of bioresorbable materials. In this work, bioresorbable zinc-magnesium alloys are 3D-printed by Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M). The goal is to manufacture load-bearing implants (e. g. patient-specific scaffolds or cages) with suitable degradation...

The integration of additive manufacturing (AM) and subtractive machining techniques, supported by digital data management and simulations, forms the process chain for hybrid manufacturing and repair of metal components. This approach facilitates the efficient restoration of damaged parts and the production of complex geometries with enhanced mechanical properties within a digitalized industry....

A primary objective of quality assurance in additive manufacturing is the regulation of defects within the components, as these have a substantial impact on the mechanical properties and durability of the resulting products. Porosity serves as a crucial indicator of process window performance and a pivotal parameter for process qualification. To determine the porosity of a given material, test...

Additive manufacturing with Laser Powder Bed Fusion (PBF-LB/M) has advanced the use of Triply Periodic Minimal Surface (TPMS) lattice structures, known for their lightweight and high surface-to-volume ratios. This study explores how residual stresses (RS) during PBF-LB/M impact the mechanical properties of these lattices. Focusing on targeted functional volume filling and optimization, we use...

The bistable mechanisms use the deformation of the compliant segment (elastic deformation of the material) to transition from one equilibrium position to another. The deformation character eliminates friction and improves the reliability of the mechanism. Both the numerical model and experiments were used to determine the parameters of the bistable mechanism. The mechanism was designed to hold...