Metal Additive Manufacturing Conference - MAMC 2024

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...

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...

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,...

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...

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...

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...

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...

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...