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This paper presents a comprehensive review on the sources of model and parameter uncertainties in laser powder bed fusion processes (L-PBF). Metal additive manufacturing (AM) involves multiple physical phenomena and parameters that potentially affect the
Carelyn E. Campbell, Greta Lindwall, Eric Lass, Fan Zhang, Mark R. Stoudt, Andrew J. Allen, Lyle E. Levine
The ability to use common computational thermodynamic and kinetic tools to study the microstructure evolution in Inconel 625 (IN625) manufactured using the additive manufacturing (AM) technique of laser powder-bed fusion is evaluated. Solidification
Max J. Lerman, Josephine Lembong, John G. Gillen, John P. Fisher
3D printing serves an important role in various biomedical research applications, including but not limited to culture systems and implantable devices. In this review, we discuss recent development in the applications of 3D printing technologies for
Shanshan Zhang, Brandon Lane, Justin G. Whiting, Kevin Chou
This study investigates the thermal conductivity of metallic powder in laser powder-bed fusion(LPBF) additive manufacturing. The intent is to utilize a methodology combining laser flash testing, finite element (FE) heat transfer modeling and an inverse
Tesfaye M. Moges, Wentao Yan, Stephen Lin, Gaurav Ameta, Jason C. Fox, Paul W. Witherell
Various sources of uncertainty that can potentially cause variability in the product quality exist at different stages of the laser powder bed fusion (L-PBF) process. To implement computational models and simulations for quality control and process
The effects of internal porosity and crystallographic texture on miniaturized Charpy absorbed energy behavior of electron beam melting (EBM) titanium alloy (Ti-6Al-4V) are shown through investigation of material in two heat treatment conditions (As-Built
Samyeon Kim, David W. Rosen, Paul Witherell, Hyunwoong Ko
Design for additive manufacturing (DFAM) provides design freedom for creating complex geometries and guides designers to ensure manufacturability of parts fabricated using additive manufacturing (AM) processes. However, there is a lack of formalized DFAM
Lily Northcutt, Sara Orski, Kalman D. Migler, Anthony Kotula
Material extrusion additive manufacturing processes force molten polymer through a printer nozzle at high (> 100 s-1) wall shear rates prior to cooling and crystallization. These high shear rates can lead to flow-induced crystallization in common polymer
Additive manufacturing (AM) has enabled the production of complex geometries such as conformal lattices, topology optimized shapes, and organic structures. These complex geometric shapes must sometimes meet functional requirements, including (1) following
Yan Lu, Zhuo Yang, Douglas Eddy, Sundar Krishnamurty
The current AM development environment is far from being mature. Both software applications and workflow management tools are very limited due to the lack of knowledge to support engineering decision makings. AM knowledge includes design rules, operation
Yan Lu, Douglas Eddy, Sundar Krishnamurty, Ian Grosse
Statistical metamodels can robustly predict manufacturing process and engineering systems design results. Various techniques, such as Kriging, polynomial regression, artificial neural network and others, are each best suited for different scenarios that
Greta Lindwall, Kil-Won Moon, Zhangqi Chen, Michael J. Mengason, Maureen E. Williams, Justin Gorham, Ji-Cheng Zhao, Carelyn E. Campbell
Diffusion in the Ti-Al-V system is studied and a CΑLPHAD diffusion mobility description is developed. Diffusion couple experiments are used to obtain information of Al and V diffusion in the α phase. This includes diffusion paths at the temperatures 923 K
Christopher U. Brown, Gregor Jacob, Antonio M. Possolo, Carlos R. Beauchamp, Max A. Peltz, Mark R. Stoudt, M A. Donmez
The goal of this study was to investigate the relationship between mechanical and material properties (including density) of manufactured nickel super alloy (IN625) using a laser powder bed fusion process and three process parameters: laser power, hatch
Maria Strantza, Rishi Ganeriwala, Bjorn Clausen, Thien Q. Phan, Lyle E. Levine, D Pagan, Wayne King, Niel Hodge, Brown Donald
The production of metallic parts via laser-powder bed fusion (L-PBF) additive manufacturing is rapidly growing. To use components produced via L-PBF in safety-critical applications, a high degree of quality confidence is required. This qualification can be
Jason C. Fox, Felix H. Kim, Zachary C. Reese, Christopher Evans
The development of additive manufacturing (AM) has allowed for production of high-value and complex parts that reduce time-to-market and cost to manufacture. A key benefit to the AM process is the capability to create lattice structures and highly complex
Zachary C. Reese, Jason C. Fox, Felix H. Kim, John Taylor, Christopher Evans
Additive manufactured (AM) components exhibit an abundance of surface textures and patterns. Past work investigating components created through laser powder bed fusion (LPBF) has shown that these patterns, specifically the chevron resulting from
Zachary C. Reese, Jason C. Fox, John Taylor, Christopher Evans
Additive manufactured (AM) components, specifically those created through laser powder bed fusion (LPBF) methods, exhibit an abundance of surface textures of varying forms and patterns. These topographies have historically been categorized solely using
Laser powder bed fusion (LPBF) is an additive manufacturing (AM) technology used to manufacture high-value metal parts. The layer-by-layer nature of the process allows complex geometries and internal features, such as conformal cooling channels, to be
Lindsey B. Bass, Justin L Milner, Thomas Gnaupel-Herold, Shawn P. Moylan
One of the key barriers to widespread adoption of additive manufacturing (AM) for metal parts is the build-up of residual stresses. In the laser-based powder bed fusion process, a laser selectively fuses metal powder layer by layer, generating significant
Bo Cheng, Brandon Lane, Justin G. Whiting, Kevin Chou
Powder-bed metal additive manufacturing (AM) utilizes a high-energy heat source scanning at the surface of a powder layer in a pre-defined area to be melted and solidified to fabricate parts layer by layer. It is known that powder-bed metal AM is primarily
Rajesh K. Ananda-Kumar, Wilfredo Moscoso-Kingsley, Gregor Jacob, Alkan Donmez, Viswanathan Madhavan
Additively manufactured (AM) and cast-wrought (CW) nickel-based super alloy (IN 625) with known processing history and quasi-static properties have been investigated for their relative machinability, in terms of tool temperature and wear, as well as force
Jarred C. Heigel, Thien Q. Phan, Jason Fox, Thomas H. Gnaupel-Herold
Hybrid Manufacturing leverages the advantages of both additive manufacturing (AM) with machining to create parts that have complex geometries, tight tolerances, and good surface finish. However, the residual stresses induced by both processes present a
This paper investigates the cutting forces during the machining of additively manufactured metals. Two pairs of workpieces were produced by powder bed direct metal selective laser sintering. These workpieces included a 17-4 stainless steel substrate