Metal Additive Manufacturing: A Review

This paper reviews the state-of-the-art of an important, rapidly emerging, manufacturing technology that is alternatively called additive manufacturing (AM), direct digital manufacturing, free form fabrication, or 3D printing, etc. A broad contextual overview of metallic AM is provided. AM has the potential to revolutionize the global parts manufacturing and logistics landscape. It enables distributed manufacturing and the productions of parts-on-demand while offering the potential to reduce cost, energy consumption, and carbon footprint. This paper explores the material science, processes, and business consideration associated with achieving these performance gains. It is concluded that a paradigm shift is required in order to fully exploit AM potential.

[1]  R. Unocic,et al.  Process efficiency measurements in the laser engineered net shaping process , 2004 .

[2]  Mary E Kinsella.  Additive Manufacturing of Superalloys for Aerospace Applications (Preprint) , 2008 .

[3]  Richard J.M. Hague,et al.  Cost estimation for rapid manufacturing - laser sintering production for low to medium volumes , 2006 .

[4]  J. Beuth,et al.  The role of process variables in laser-based direct metal solid freeform fabrication , 2001 .

[5]  S. Kelly,et al.  Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part II. Thermal modeling , 2004 .

[6]  Ingomar Kelbassa,et al.  Laser Additive Manufacturing , 2010 .

[7]  J. Foyos,et al.  Tensile Properties and Microstructures of Laser-Formed Ti-6Al-4V , 2011 .

[8]  Joseph Pegna,et al.  Environmental impacts of rapid prototyping: an overview of research to date , 2006 .

[9]  Samuel G. Lambrakos,et al.  A General Algorithm for Inverse Modeling of Layer-By-Layer Liquid-Metal Deposition , 2010 .

[10]  Samuel G. Lambrakos,et al.  An Algorithm for Inverse Modeling of Layer-by-Layer Deposition Processes , 2009, Journal of materials engineering and performance (Print).

[11]  David L. Bourell,et al.  Sustainability Study in Selective Laser Sintering - An Energy Perspective , 2010 .

[12]  Angappa Gunasekaran,et al.  Design of activity-based costing in a small company: a case study , 1999 .

[13]  L. Murr,et al.  Microstructural Architecture, Microstructures, and Mechanical Properties for a Nickel-Base Superalloy Fabricated by Electron Beam Melting , 2011 .

[14]  William E. Frazier,et al.  Qualifying of metallic materials and structures for aerospace applications , 2001 .

[15]  Wen-Hsien Tsai,et al.  Activity-based costing model for joint products , 1996 .

[16]  Robert L. Mason,et al.  Fatigue Life of Titanium Alloys Fabricated by Additive Layer Manufacturing Techniques for Dental Implants , 2013, Metallurgical and Materials Transactions A.

[17]  Bernd Baufeld,et al.  Mechanical Properties of INCONEL 718 Parts Manufactured by Shaped Metal Deposition (SMD) , 2012, Journal of Materials Engineering and Performance.

[18]  Terry Wohlers,et al.  Additive Manufacturing: Status and Opportunities , 2012 .

[19]  J. Schoenung,et al.  Thermal Behavior and Microstructural Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part I. Numerical Calculations , 2008 .

[20]  Julie M. Schoenung,et al.  Thermal Behavior and Microstructure Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part II. Experimental Investigation and Discussion , 2008 .

[21]  S. L. Semiatin,et al.  The laser additive manufacture of Ti-6Al-4V , 2001 .

[22]  C. Colin,et al.  As-Fabricated and Heat-Treated Microstructures of the Ti-6Al-4V Alloy Processed by Selective Laser Melting , 2011 .

[23]  P. Colegrove,et al.  Microstructure and Mechanical Properties of Wire and Arc Additive Manufactured Ti-6Al-4V , 2013, Metallurgical and Materials Transactions A.

[24]  E. Herderick,et al.  Additive Manufacturing of Metals: A Review , 2011 .

[25]  Julie M. Schoenung,et al.  Thermal Behavior and Microstructure Evolution during Laser Deposition with LENS?: Part II Experimental Investigation and Discussion. , 2008 .

[26]  Angappa Gunasekaran,et al.  Activity-based management in a small company: A case study , 2000 .

[27]  Steven J. Skerlos,et al.  Environmental aspects of laser-based and conventional tool and die manufacturing , 2007 .

[28]  S. Kelly.  Thermal and Microstructure Modeling of Metal Deposition Processes with Application to Ti-6Al-4V , 2004 .