Recent Advances in Additive Manufacturing Processes, Monitoring, and Thermal Applications for Advanced Industrial Components

Litzinger Thomas Hadgraft

doi:10.61424/ijans.v2i2.1061

Authors

Litzinger Thomas Hadgraft Independent Researcher, Massachusetts Institute of Technology (MIT), USA

DOI:

https://doi.org/10.61424/ijans.v2i2.1061

Keywords:

Additive manufacturing, In process monitoring, Thermal management, Microstructure characterization, Intelligent manufacturing

Abstract

Additive manufacturing (AM) is no longer just a prototyping technique but has become a serious technology for the production of very complex industrial components with high performance properties, which is still in the process of reaching lightweight construction standards. Additive manufacturing (AM) is now no longer only a prototyping technique, but has become a serious manufacturing technique, which is still being developed to reach lightweight construction standards, in order to produce very complex components with high performance properties. This review summarizes the latest advances of AM processes, in process monitoring, in thermal applications, materials characterisation and in industrial implementation. Significant progress in powder bed fusion, directed energy deposition and associated deposition technologies have facilitated the processing of complex architectures, high melting point materials, multi material structures, and functionally graded architectures. Specific focus is on thermal management by conformal cooling channels, optimized heat exchangers and integrated thermal structures in aerospace, turbine, automotive, medical and energy industry. Machine learning and predictive modelling, in combination with the digital twin and closed loop control, are demonstrated to be opportunities for adaptive parameter optimisation and increased process certainty. Thermal analysis, X ray diffraction, electron backscatter diffraction, metallography and porosity assessment are also deemed as essential tools for establishing links between processing conditions, microstructure, thermal behaviour, and final component performance. Although great strides have been made, there are still limitations in the form of residual stress, porosity, thermal distortion, processing variability, high equipment costs, post processing requirements, scalability, data accessibility and certification.

Downloads

Download data is not yet available.

References

Baufeld B., (2023) Wire electron beam additive manufacturing of copper, J. Phys. Conf. Ser., vol. 2443, p. 012001, 2023. doi: 10.1088/1742-6596/2443/1/012001.

Chattopadhyay S., Mahapatra S. D., and Mandal N. K., (2024) Advancements and challenges in additive manufacturing: A comprehensive review, Eng. Res. Express, vol. 6, no. 1, p. 012505, 2024. doi: 10.1088/2631-8695/ad30b1.

Chénier F., Parent G., Leblanc M., Bélaise C., and Andrieux M., (2023) Using a quantitative assessment of propulsion biomechanics in wheelchair racing to guide the design of personalized gloves: A case study, arXiv, 2023. doi: 10.1080/10255842.2024.2311324.

Du W., Bai Q., and Zhang B., (2016) A novel method for additive/subtractive hybrid manufacturing of metallic parts, Procedia Manuf., vol. 5, pp. 1018-1030, 2016. doi: 10.1016/j.promfg.2016.08.067.

Flynn J. M., Shokrani A., Newman S. T., and Dhokia V., (2016) Hybrid additive and subtractive machine tools-Research and industrial developments, Int. J. Mach. Tools Manuf., vol. 101, pp. 79-101, 2016. doi: 10.1016/j.ijmachtools.2015.11.007.

Hollister S. J. and Bergman T. L., (2004) Biomedical applications of integrated additive/subtractive manufacturing, in Additive/Subtractive Manufacturing Research and Development in Europe, Baltimore, MD, USA: World Technology Evaluation Center, Inc., 2004, pp. 55-62.

Hossain M. A., Badugu D., and Seelu B., (2023) Multi-material and functionally graded additive manufacturing for next-generation mechanical and thermal engineering components, Brit. J. Multidiscip. Stud., vol. 1, no. 2, pp. 11–26, 2023, doi: 10.32996/bjmss.2023.2.2.2.

Hossain M. A., Barman S. C., Pi W., and Islam S. M. T., (2022) A study on hybrid manufacturing systems integrating additive manufacturing and CNC machining for high-precision industrial component production, J. Mech. Civil Ind. Eng., vol. 3, no. 2, pp. 24–41, 2022, doi: 10.32996/jmcie.2022.3.2.4.

Hossain M. A., Bhuiyan M. A. A., Rahman A., and Hasan D. W., (2024) Integration of artificial intelligence for real-time monitoring and process control in metal additive manufacturing systems, J. Mech. Civil Ind. Eng., vol. 5, no. 3, pp. 08–28, 2024, doi: 10.32996/jmcie.2024.5.3.2.

Hossain M. A., Dangol S., Hasan D. W., and Badugu D., (2023) Thermal performance study of additively manufactured compact heat exchangers for industrial energy systems, J. Mech. Civil Ind. Eng., vol. 4, no. 4, pp. 86–103, 2023, doi: 10.32996/jmcie.2023.4.4.9.

Hossain M. A., Pi W., Islam S. M. T., and Lide M. I., (2021) Smart manufacturing framework for real-time process monitoring, predictive maintenance, and quality control in advanced mechanical production systems, J. Mech. Civil Ind. Eng., vol. 2, no. 1, pp. 11–24, 2021, doi: 10.32996/jmcie.2021.2.1.3.

Jakimiuk A., Skwira A., Wróbel Z., and Wróbel Z., (2024) 3D-printed patient-specific implants made of polylactide (PLDLLA) and β-tricalcium phosphate (β-TCP) for corrective osteotomies of the distal radius, 3D Print. Med., vol. 10, p. 42, 2024. doi: 10.1186/s41205-024-00240-z.

Jayawardane H., Davies I. J., Gamage J. R., John M., and Biswas W. K., (2023) Sustainability perspectives-A review of additive and subtractive manufacturing, Sustain. Manuf. Serv. Econ., vol. 2, p. 100015, 2023. doi: 10.1016/j.smse.2023.100015.

Jiménez A., Bidare P., Hassanin H., Tarlochan F., Dimov S., and Essa K., (2021) Powder-based laser hybrid additive manufacturing of metals: A review, Int. J. Adv. Manuf. Technol., vol. 114, pp. 63-96, 2021. doi: 10.1007/s00170-021-06855-4.

Joghan H. D., Hölker-Jäger R., Komodromos A., and Tekkaya A. E., (2023) Hybrid additive manufacturing of forming tools, Automot. Innov., vol. 6, pp. 311-323, 2023. doi: 10.1007/s42154-023-00239-y.

Jung S., Kara L. B., Nie Z., Simpson T. W., and Whitefoot K. S., (2023) Is additive manufacturing an environmentally and economically preferred alternative for mass production? Environ. Sci. Technol., vol. 57, no. 17, pp. 6373-6386, 2023. doi: 10.1021/acs.est.2c04927.

Kapil S., Rajput A. S., and Sarma R., (2022) Hybridization in wire arc additive manufacturing, Front. Mech. Eng., vol. 8, p. 981846, 2022. doi: 10.3389/fmech.2022.981846.

Karunakaran K. P., Suryakumar S., Pushpa V., and Akula S., (2010) Low cost integration of additive and subtractive processes for hybrid layered manufacturing, Robot. Comput.-Integr. Manuf., vol. 26, pp. 490-499, 2010. doi: 10.1016/j.rcim.2010.03.008.

Krimpenis A. A. and Iordanidis D. M., (2023) Design and analysis of a desktop multi-axis hybrid milling-filament extrusion CNC machine tool for non-metallic materials, Machines, vol. 11, no. 6, p. 637, 2023. doi: 10.3390/machines11060637.

Lalegani D M., Serjouei A., Zolfagharian A., Fotouhi M., Moradi M., Ariffin M. K. A., and Bodaghi M., (2022) A review on additive/subtractive hybrid manufacturing of directed energy deposition (DED) process, Adv. Powder Mater., vol. 1, no. 4, p. 100054, 2022. doi: 10.1016/j.apmate.2022.100054.

Lauwers B., Klocke F., Klink A., Tekkaya A. E., Neugebauer R., and Mcintosh D., (2014) Hybrid processes in manufacturing, CIRP Ann.-Manuf. Technol., vol. 63, no. 2, pp. 561-583, 2014. doi: 10.1016/j.cirp.2014.05.003.

Liu R., Wang Z., Sparks T., Liou F., and Newkirk J., (2017) Aerospace applications of laser additive manufacturing, in Laser Additive Manufacturing: Materials, Design, Technologies, and Applications, Cambridge, UK: Woodhead Publishing, 2017, pp. 351-371. doi: 10.1016/B978-0-08-100433-3.00013-0.

Loyda A., Arizmendi M., Ruiz de Galarreta S., Rodriguez-Florez N., and Jimenez A., (2023) Meeting high precision requirements of additively manufactured components through hybrid manufacturing, CIRP J. Manuf. Sci. Technol., vol. 40, pp. 199-212, 2023. doi: 10.1016/j.cirpj.2022.11.011.

Marques A., Guimarães B., Bartolomeu F., Miranda G., Silva F. S., and Carvalho Ó., (2023) Multi-material Inconel 718-aluminium parts targeting aerospace applications: A suitable combination of low-weight and thermal properties, Opt. Laser Technol., vol. 158, p. 108913, 2023. doi: 10.1016/j.optlastec.2022.108913.

Mechete A., Tarlochan F., and Kucukvar M., (2023) A review of conventional versus additive manufacturing for metals: Life-cycle environmental and economic analysis, Sustainability, vol. 15, no. 16, p. 12299, 2023. doi: 10.3390/su151612299.

Merklein M., Junker D., Schaub A., and Neubauer F., (2016) Hybrid additive manufacturing technologies-An analysis regarding potentials and applications, Phys. Procedia, vol. 83, pp. 549-559, 2016. doi: 10.1016/j.phpro.2016.08.057.

Mertkan İ. A., Tezel T., and Kovan V., (2022) Surface and dimensional quality of thermoplastics manufactured by additive manufacturing-based hybrid manufacturing, Res. Sq., preprint, 2022. doi: 10.21203/rs.3.rs-2229678/v1.

Nagamatsu H., Sasahara H., Mitsutake Y., and Hamamoto T., (2020) Development of a cooperative system for wire and arc additive manufacturing and machining, Addit. Manuf., vol. 31, p. 100896, 2020. doi: 10.1016/j.addma.2019.100896.

Nau B., Roderburg A., and Klocke F., (2011) Ramp-up of hybrid manufacturing technologies, CIRP J. Manuf. Sci. Technol., vol. 4, no. 3, pp. 313-316, 2011. doi: 10.1016/j.cirpj.2011.04.003.

Pragana J. P. M., Sampaio R. F. V., Bragança I. M. F., Silva C. M. A., and Martins P. A. F., (2021) Hybrid metal additive manufacturing: A state-of-the-art review, Adv. Ind. Manuf. Eng., vol. 2, p. 100032, 2021. doi: 10.1016/j.aime.2021.100032.

Prasad G., Arunav H., Dwight S., Ghosh M. B., Jayadev A., and Nair D. I., (2024) Advancing sustainable practices in additive manufacturing: A comprehensive review on material waste recyclability, Sustainability, vol. 16, no. 23, p. 10246, 2024. doi: 10.3390/su162310246.

Praveena B. A., Lokesh N., Buradi A., Santhosh N., Praveena B. L., and Vignesh R., (2022) A comprehensive review of emerging additive manufacturing (3D printing technology): Methods, materials, applications, challenges, trends and future potential, Mater. Today Proc., vol. 52, pp. 1309-1313, 2022. doi: 10.1016/j.matpr.2021.11.059.

Saxena K. K., Bellotti M., Qian J., Reynaerts D., Lauwers B., and Luo X., (2018) Chapter 2-Overview of Hybrid Machining Processes, in Hybrid Machining, London, UK: Academic Press, 2018, pp. 21-41. doi: 10.1016/B978-0-12-813059-9.00002-6.

Schuh G., Kreysa J., and Orilski S., (2009) Roadmap 'Hybride Produktion', Z. Wirtsch. Fabr., vol. 104, no. 5, pp. 385-391, 2009. doi: 10.3139/104.110072.

Sebbe N. P. V., Fernandes F., Sousa V. F. C., and Silva F. J. G., (2022) Hybrid manufacturing processes used in the production of complex parts: A comprehensive review, Metals, vol. 12, no. 11, p. 1874, 2022. doi: 10.3390/met12111874.

Soe A. N., Sombatmai A., Promoppatuma P., Srimaneepong V., Trachoo V., and Pandee P., (2024) Effect of post-processing treatments on surface roughness and mechanical properties of laser powder bed fusion of Ti-6Al-4V, J. Mater. Res. Technol., vol. 32, pp. 3788-3803, 2024. doi: 10.1016/j.jmrt.2024.08.197.

Sun G. F., Shen X. T., Wang Z. D., Zhan M. J., Yao S., Zhou R., and Ni Z. H., (2019) Laser metal deposition as repair technology for 316L stainless steel: Influence of feeding powder compositions on microstructure and mechanical properties, Opt. Laser Technol., vol. 109, pp. 71-83, 2019. doi: 10.1016/j.optlastec.2018.07.051.

Williams S. W., Martina F., Addison A. C., Ding J., Pardal G., and Colegrove P., (2016) Wire + Arc Additive Manufacturing, Mater. Sci. Technol., vol. 32, no. 7, pp. 641-647, 2016. doi: 10.1179/1743284715Y.0000000073.

Xu Z., Ouyang W., Jia S., Jiao J., Zhang M., and Zhang W., (2020) Cracks repairing by using laser additive and subtractive hybrid manufacturing technology, J. Manuf. Sci. Eng., vol. 142, no. 3, p. 031006, 2020. doi: 10.1115/1.4046161.

Yue W., Zhang Y., Zheng Z., and Lai Y., (2024) Hybrid laser additive manufacturing of metals: A review, Coatings, vol. 14, no. 3, p. 315, 2024. doi: 10.3390/coatings14030315.

Zhu Z., Dhokia V. G., Nassehi A., and Newman S. T., (2013) A review of hybrid manufacturing processes-state of the art and future perspectives, Int. J. Comput. Integr. Manuf., vol. 26, no. 7, pp. 596-615, 2013. doi: 10.1080/0951192X.2012.749530.