Print

2023 №11 (05) DOI of Article
10.37434/tpwj2023.11.06
2023 №11 (07)

The Paton Welding Journal 2023 #11
The Paton Welding Journal, 2023, #11, 46-52 pages

Additive manufacturing of structural elements on a thin-walled base: challenges and difficulties (Review)

M.V. Sokolovskyi1, A.V. Bernatskyi1, N.O. Shamsutdinova1, Yu.V. Yurchenko1, O.O. Danileiko2

1E.O. Paton Electric Welding Institute of the NASU.. 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: m_sokolovskyi@paton.kiev.ua
2E.O. Paton Education&Research Institute of Materials Science and Welding of the National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute”. 37 Beresteysky Ave. (Peremohy), 03056, Kyiv

Abstract
In the work, a literary review of materials was conducted, devoted to different areas of studying selective laser melting (SLM) and selective laser sintering (SLS) technologies in order to analyze the processes associated with selective laser surfacing occurring during SLM and SLS, as well as the impact of technological measures on the final structure, mechanical and service characteristics of a manufactured part in the additive manufacturing of structural elements on a thin-walled base. The main tasks of research works analyzed in the review were studies focused on the features of structural elements formation on a thin-walled by means of SLM and SLS technologies: modelling of additive manufacturing processes; aspects of planning experiments and manufacturing processes; studying the course of SLM and SLS processes in the given conditions; need in pre- or post-treatment of material; as well as analysis of the end microstructure and characteristics of specimens manufactured using these technologies. Based on the results of literary analysis, problems were identified and the prospects of using SLM and SLS processes were considered during the formation of structural elements on a thin-walled base. A number of aspects were justified, on which it is necessary to pay attention during studies of SLM and SLS processes when working with a thin-walled base. 36 Ref., 9Fig.
Keywords: selective laser melting (SLM), additive manufacturing, selective laser sintering (SLS), thin-walled products


Received: 10.07.2023
Accepted: 07.12.2023

References

1. Del Sol, I., Rivero, A., Lacalle, L., Gámez, A. (2012) Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches. Materials, 12. https://doi.org/10.3390/ma12122012
2. Singh R., Gupta A., Tripathi O. et al. (2020) Powder bed fusion process in additive manufacturing: An overview. Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2020.02.635
3. Mazumder J. (2017) 1 - Laser-aided direct metal deposition of metals and alloys. Editor(s): Milan Brandt. In Woodhead Publishing Series in Electronic and Optical Materials. Laser Additive Manufacturing. Woodhead Publishing, 21-53. ISBN 9780081004333. https://doi.org/10.1016/B978-0-08-100433-3.00001-4
4. Yushchenko, K.A., Borysov, Yu.S., Kuznetsov, V.D., Korzh, V.M. (2007) Surface Engineering: Manual. Kyiv, Naukova Dumka [in Ukrainian]. ISBN 978-966-00-0655-3
5. Li Yuan, Songlin Ding, Cuie Wen. (2019) Additive manufacturing technology for porous metal implant applications and triple minimal surface structures: A review, Bioactive Materials, 4, 56-70. ISSN 2452-199X. https://doi.org/10.1016/j.bioactmat.2018.12.003
6. Kritskiy, D., Pohudina, O., Kovalevskyi, M. et al. (2022) Powder Mixtures Analysis for Laser Cladding Using OpenCV Library. In: Nechyporuk, M., Pavlikov, V., Kritskiy, D. (eds) Integrated Computer Technologies in Mechanical Engineering - 2021. ICTM 2021. Lecture Notes in Networks and Systems, 367. Springer, Cham. https://doi.org/10.1007/978-3-030-94259-5_72
7. Duriagina, Z., Kulyk, V., Kovbasiuk, T. et al. (2021) Synthesis of Functional Surface Layers on Stainless Steels by Laser Alloying. Metals, 11, 434. https://doi.org/10.3390/met11030434
8. Korzhyk, V., Khaskin, V., Voitenko, O. et al. (2017). Welding Technology in Additive Manufacturing Processes of 3D Objects. In Materials Science Forum, 906, 121-130. Trans Tech Publications, Ltd. https://doi.org/10.4028/www.scientific.net/MSF.906.121
9. Lesyk, D.A., Martinez, S., Pedash, O.O. et al. (2022) Nickel Superalloy Turbine Blade Parts Printed by Laser Powder Bed Fusion: Thermo-Mechanical Post-processing for Enhanced Surface Integrity and Precipitation Strengthening. J. of Materi Eng and Perform, 31, 6283-6299. https://doi.org/10.1007/s11665-022-06710-x
10. Peleshenko, S., Korzhyk, V., Voitenko, O. et al. (2017) Analysis of the current state of additive welding technologies for manufacturing volume metallic products (review). Eastern-European Journal of Enterprise Technologies, 3/1, 42-52. https://doi.org/10.15587/1729-4061.2017.99666
11. Kumar, S. (2014) 10.05 - Selective Laser Sintering/Melting, Editor(s): Saleem Hashmi, Gilmar Ferreira Batalha, Chester J. Van Tyne, Bekir Yilbas. Comprehensive Materials Processing, Elsevier, 93-134. ISBN 9780080965338. https:// doi.org/10.1016/B978-0-08-096532-1.01003-7 https://doi.org/10.1016/B978-0-08-096532-1.01003-7
12. Serin, G., Kahya, M, Unver, H. et al. (2018) A Review Of Additive Manufacturing Technologies. Conference: The 17th International Conference on Machine Design and Production, Bursa, Turkey, January 2018.
13. Joel C. Najmon, Sajjad Raeisi, Andres Tovar (2019) 2 - Review of additive manufacturing technologies and applications in the aerospace industry, Editor(s): Francis Froes, Rodney Boyer, Additive Manufacturing for the Aerospace Industry, Elsevier, 7-31. ISBN 9780128140628. https://doi.org/10.1016/B978-0-12-814062-8.00002-9
14. Del Sol, I., Rivero, A., Lacalle, L., Gámez, A. (2019) Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches. Materials, 12, 2012.. https://doi.org/10.3390/ma12122012
15. Adjamsky, S.V., Sazanishvili, Z.V., Tkachov, Y.V. et al. (2021) Influence of the Time Interval between the Deposition of Layers by the SLM Technology on the Structure and Properties of Inconel 718 Alloy. Mater Sci, 57, 9-16. https://doi.org/10.1007/s11003-021-00508-3
16. Sun, Z., Tan, X., Tor, S. Chua, C. (2018) Simultaneously enhanced strength and ductility for 3D-printed stainless steel 316L by selective laser melting. NPG Asia Materials, 10(4), 127-136. https://doi.org/10.1038/s41427-018-0018-5
17. Wang, Y., Voisin, T., McKeown, J. et al. (2017) Additively manufactured hierarchical stainless steels with high strength and ductility. Nature Materials, 17(1), 63-71. https://doi.org/10.1038/nmat5021
18. Yang, W., Tang, Y. (1998) Design optimization of cutting parameters for turning operations based on the Taguchi method. Journal of Materials Processing Technology, 84(1-3), 122- 129. https://doi.org/10.1016/S0924-0136(98)00079-X
19. Gibson, D. Rosen, B. Stucker (2015) Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping and Direct Digital Manufacturing Ch.10 (Springer, New York, 2015). https://doi.org/10.1007/978-1-4939-2113-3
20. Pulin, Nie, Ojo, O.A., Zhuguo, Li (2014) Numerical modeling of microstructure evolution during laser additive manufacturing of a nickel-based superalloy. Acta Materialia, 77, 85-95, ISSN 1359-6454. https://doi.org/10.1016/j.actamat.2014.05.039
21. Mukherjee, T., Manvatkar, V., De, A., DebRoy, T. (2017) Dimensionless numbers in additive manufacturing. J. Appl. Phys., 121, 064904. https://doi.org/10.1063/1.4976006
22. Yang, T., Xie, D., Yue, W. et al. (2019) Distortion of Thin-Walled Structure Fabricated by Selective Laser Melting Based on Assumption of Constraining Force-Induced Distortion. Metals., 9(12), 1281. https://doi.org/10.3390/met9121281
23. Zhonghua, Li, Renjun, Xu, Zhengwen, Zhang, Ibrahim, Kucukkoc (2018) The influence of scan length on fabricating thin-walled components in selective laser melting. International Journal of Machine Tools and Manufacture, 126, 1-12. ISSN 0890-6955. https://doi.org/10.1016/j.ijmachtools.2017.11.012
24. Eberhard Abele, Hanns A. Stoffregen, Kniepkamp, M. et al. (2015) Selective laser melting for manufacturing of thinwalled porous elements. Journal of Materials Processing Technology, 215, 114-122. ISSN 0924-0136. https://doi.org/10.1016/j.jmatprotec.2014.07.017
25. Jichang, Liu, Lijun, Li (2005) Effects of powder concentration distribution on fabrication of thin-wall parts in coaxial laser cladding. Optics & Laser Technology, 37, 4, 287-292. ISSN 0030-3992. https://doi.org/10.1016/j.optlastec.2004.04.009
26. Xu Niu, Ruixian Qin, Yunzhuo Lu, Bingzhi Chen (2021) Energy Absorption Behaviors of Laser Additive Manufactured Aluminium Alloy Thin-Walled Tube Tailored by Heat Treatment. Materials Transactions, 62, 2, 278-283. https://doi.org/10.2320/matertrans.MT-M2020271
27. AlMangour, B., Grzesiak, D., Yang, J. (2017) Scanning strategies for texture and anisotropy tailoring during selective laser melting of TiC/316L stainless steel nanocomposites. Journal of Alloys and Compounds, 728, 424-435. https://doi.org/10.1016/j.jallcom.2017.08.022
28. Zhao, C., Bai, Y., Zhang, Y. et al. (2021) Influence of scanning strategy and building direction on microstructure and corrosion behaviour of selective laser melted 316L stainless steel. Materials & Design, 209, id.109999. https://doi.org/10.1016/j.matdes.2021.109999
29. Bambach, M, Sviridov, A, Weisheit, A, Schleifenbaum, JH. (2017) Case Studies on Local Reinforcement of Sheet Metal Components by Laser Additive Manufacturing. Metals., 7(4), 113. https://doi.org/10.3390/met7040113
30. Bhrigu Ahuja, Adam Schaub, Michael Karg et al. (2015) High power laser b eam melting of Ti-6Al-4V on formed sheet metal to achieve hybrid structures. Proc. SPIE 9353, Laser 3D Manufacturing II, 93530X (16 March 2015). https://doi.org/10.1117/12.2082919
31. Heilemann, M., Beckmann, J., Konigorski, D., Emmelmann, C. (2018) Laser metal deposition of bionic aluminum supports: reduction of the energy input for additive manufacturing of a fuselage. Procedia CIRP, 74, 136-139. ISSN 2212-8271. https://doi.org/10.1016/j.procir.2018.08.063
32. Vekilov, S.Sh., Lipovskyi, V.I., Marchan, R.A., Bondarenko, O.Ie. (2021) Specifics of using of technology in SLM manufacture for LRE components. J. of Rocket-Space Technology, 29, 112-123. https://doi.org/10.15421/452112
33. Kelly, S.M., Kampe, S.L. Microstructural Evolution in Laser-Deposited Multilayer Ti-6Al-4V Builds: Part I. (2004) Microstructural Characterization. Metallurgical and materials transactions, 35A, June 1861. https://doi.org/10.1007/s11661-004-0094-8
34. Heilemann, M., Möller, M., Emmelmann, C. et al. (2017) Laser Metal Deposition of Ti-6Al-4V Strcutures: Analysis of the Build Height Dependent Microstructure and Mechanical Properties. MS&T 2017. https://doi.org/10.7449/2017/mst_2017_312_320
35. Schaub, A., Ahuja, B., Karg, M. et al. (2014) Fabrication and Characterization of Laser Beam Melted Ti-6Al-4V Geometries on Sheet Metal. DDMC 2014 Fraunhofer Direct Digital Manufacturing Conference, Berlin, Germany.
36. Lesyk, D., Martinez, S., Dzhemelinkyi, V., Lamikiz, A. (2020) Additive Manufacturing of the Superalloy Turbine Blades by Selective Laser Melting: Surface Quality. Microstructure and Porosity. In: Karabegović, I. (eds) New Technologies, Development and Application III. NT 2020. Lecture Notes in Networks and Systems, 128. Springer, Cham. https://doi.org/10.1007/978-3-030-46817-0_30

Suggested Citation

M.V. Sokolovskyi, A.V. Bernatskyi, N.O. Shamsutdinova, Yu.V. Yurchenko, O.O. Danileiko (2023) Additive manufacturing of structural elements on a thin-walled base: challenges and difficulties (Review). The Paton Welding J., 11, 46-52.