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Search results for: WIRE ARC ADDITIVE MANUFACTURING
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Wire Arc Additive Manufactured Mild Steel and Austenitic Stainless Steel Components: Microstructure, Mechanical Properties and Residual Stresses
PublicationWire arc additive manufacturing (WAAM) is an additive manufacturing process based on the arc welding process in which wire is melted by an electric arc and deposited layer by layer. Due to the cost and rate benefits over powder-based additive manufacturing technologies and other alternative heat sources such as laser and electron beams, the process is currently receiving much attention in the industrial production sector. The gas...
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Novel Cold Crucible Ultrasonic Atomization Powder Production Method for 3D Printing
Publication: A new powder production method has been developed to speed up the search for novel alloys for additive manufacturing. The technique involves an ultrasonically agitated cold crucible installed at the top of a 20 kHz ultrasonic sonotrode. The material is melted with an electric arc and undergoes pulverization with standing wave vibrations. Several different alloys in various forms, including noble and metallic glass alloys, were...
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Immersive Technologies that Aid Additive Manufacturing Processes in CBRN Defence Industry
PublicationTesting unique devices or their counterparts for CBRN (C-chemical, B-biological, R-radiological, N-nuclear) defense relies on additive manufacturing processes. Immersive technologies aid additive manufacturing. Their use not only helps understand the manufacturing processes, but also improves the design and quality of the products. This article aims to propose an approach to testing CBRN reconnaissance hand-held products developed...
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Additive Manufacturing as a Solution to Challenges Associated with Heat Pipe Production
PublicationThe aim of this review is to present the recent developments in heat pipe production, which respond to the current technical problems related to the wide implementation of this technology. A novel approach in HP manufacturing is to utilise hi-tech additive manufacturing techniques where the most complicated geometries are fabricated layer-by-layer directly from a digital file. This technology might be a solution to various challenges...
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MULTI-CRITERIA COMPARATIVE ANALYSIS OF THE USE OF SUBTRACTIVE AND ADDITIVE TECHNOLOGIES IN THE MANUFACTURING OF OFFSHORE MACHINERY COMPONENTS
PublicationThe dynamic development of additive manufacturing technologies, especially over the last few years, has increased the range of possible industrial applications of 3D printed elements. This is a consequence of the distinct advantages of additive techniques, which include the possibility of improving the mechanical strength of products and shortening lead times. Offshore industry is one of these promising areas for the application...
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Advancements in the Additive Manufacturing of Magnesium and Aluminum Alloys through Laser-Based Approach
PublicationComplex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives such as reduced part numbers, greater functionality, and lightweight, among others. Polymers, metals, and ceramics are the few materials that can be used in AM technology, but metallic materials (Magnesium and Aluminum) are attracting more attention from the research and industrial point of view. Understanding the role...
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Quasistatic and fatigue behavior of an AISI H13 steel obtained by additive manufacturing and conventional method
PublicationThis work aims to compare the mechanical behavior of an AISI H13 steel obtained by additive manufacturing with that obtained by conventional manufacturing methods. The average values of the ultimate tensile strength (UTS) and ductility obtained for the specimens produced by the conventional method were equal to 658 MPa and 18%, respectively, which compares with 503 MPa and 0.75% registered for the selective laser melting (SLM)...
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Uncertainty Quantification of Additive Manufacturing Post-Fabrication Tuning of Resonator-Based Microwave Sensors
PublicationReconfigurability, especially in terms of the ability of adjusting the operating frequency, has become an important prerequisite in the design of modern microwave components and systems. It is also pertinent to microwave sensors developed for a variety of applications such as characterization of material properties of solids or liquids. This paper discusses uncertainty quantification of additive-manufacturing-based post-fabrication...
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Development of Technical Creativity Featuring Modified TRIZ-AM Inventive Principle to Support Design for Additive Manufacturing
Publicationhe design for additive manufacturing (DFAM) processing was introduced to fully utilise the design freedom provided by additive manufacturing (AM). Consequently, appropriate design methodologies have become essential for this technology. Recently, many studies have identified the importance of DFAM method utilisation to produce AM parts, and TRIZ is a strategy used to formalise design methodologies....
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Structural and Material Determinants Influencing the Behavior of Porous Ti and Its Alloys Made by Additive Manufacturing Techniques for Biomedical Applications
PublicationOne of the biggest challenges in tissue engineering is the manufacturing of porous structures that are customized in size and shape and that mimic natural bone structure. Additive manufacturing is known as a sufficient method to produce 3D porous structures used as bone substitutes in large segmental bone defects. The literature indicates that the mechanical and biological properties of scaffolds highly depend on geometrical features...
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Fatigue fracture morphology of AISI H13 steel obtained by additive manufacturing
PublicationThe paper focuses on researching the effect of fatigue loading on metallic structure, lifetime, and fracture surface topographies in AISI H13 steel specimens obtained by selective laser melting (SLM). The topography of the fracture surfaces was measured over their entire area, according to the entire total area method, with an optical three-dimensional surface measurement system. The fatigue results of the SLM 3D printed steel...
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Geometric Specification of Non-Circular Pulleys Made with Various Additive Manufacturing Techniques
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Quasistatic and fatigue behavior of an AISI H13 steel obtained by additive manufacturing and conventional method
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Microstructural and Mechanical Properties of Novel Co-Free Maraging Steel M789 Prepared by Additive Manufacturing
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A novel method of creating thermoplastic chitosan blends to produce cell scaffolds by FDM additive manufacturing
PublicationDue to its remarkable and promising biological and structural properties, chitosan has been widely studied in several potential applications in the biomedical sector. Attempts are being made to use this polymer and its properties in thermoplastics dedicated to 3D printing in FDM technology. However, chitosan can be processed only from acid solution, which limits its applications. The paper presents a new path for the production...
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Effect of multiaxial bending-torsion loading on fracture surface parameters in high-strength steels processed by conventional and additive manufacturing
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Resonator-Loaded Waveguide Notch Filters with Broad Tuning Range and Additive-Manufacturing-Based Operating Frequency Adjustment Procedure
PublicationThis article presents a new class of ring-resonator-loaded waveguide notch filters with a broad tuning range, low cost, and improved performance. The proposed approach employs a comple-mentary asymmetric split ring resonator coupled to a microstrip transmission line and excited in a rectangular waveguide. An equivalent circuit model is proposed to explain the working principle of the proposed notch filter. The adjustment of the...
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Mechanical Properties of 3D Printed Parts and Their Injection Molded Alternatives Subjected to Environmental Aging
PublicationAdditive manufacturing is the technology used in medical, industrial, or lifestyle applications. The scientific literature include works reporting various manufacturing parameters’ influence on changes in additive manufacturing components’ mechanical behavior, especially with fused filament fabrication (FFF). The changes in mechanical strength and toughness of FFF compared to injection molding parts were studied. In the study,...
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Tensile and Fatigue Behavior of Additive Manufactured Polylactide
PublicationThis article presents the results of monotonic tensile and fatigue tests conducted on commercial polylactide or polylactic acid (PLA). The results of fatigue tests for this material present in the literature are limited, especially for additive manufactured elements. The specimens were manufactured using the injection molding and the fused filament fabrication (FFF) method. The FFF specimens were divided into five subgroups, depending...
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Analysis of the Possibilities of Applying 3D Print Methods for the Needs of Ship-Building Industry
PublicationArticle presents the analysis of applying additive and hybrid manufacturing methods and its impact on dynamic stiffness of prepared samples. Dynamic analysis of the handle bracket specimens consisted in plotting the resonance curves and using these curves to estimate the dynamic stiffness of elements produced with additive manufacturing technology. Authors focused especially on 3D print in Fused Deposiotion Modeling/Fused Filament...
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Teaching of Robot Arm Programming - Tasks with Increasing Difficulty
PublicationThe article describes education techniques using robotics. For example, educational exercises on programming the Nachi MZ04 robotic arm are presented. The exercises use a wooden railroad toy model and elements printed in additive manufacturing technology. The exercises have increasing difficulty and can be used to educate young people in high school and specialized higher engineering studies (both bachelor's and master's).
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Project-Based Collaborative Research and Training Roadmap for Manufacturing Based on Industry 4.0
PublicationThe importance of the economy being up to date with the latest developments, such as Industry 4.0, is more evident than ever before. Successful implementation of Industry 4.0 principles requires close cooperation of industry and state authorities with universities. A paradigm of such cooperation is described in this paper stemming from university partners with partly overlapping and partly complementary areas of expertise in manufacturing....
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Diffusible hydrogen management in underwater wet self-shielded flux cored arc welding
PublicationThis article reports the effect of underwater wet welding parameters and conditions on the diffusible hydrogen content in deposited metal for welding with a self-shielded flux cored wire. The diffusible hydrogen content in deposited metal was determined using the glycerin method according to the Plackett-Burman design determining the significance of the effect of the stick out length, welding current, arc voltage, travel speed...
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THE USE OF THE Ti-13Zr-13Nb ALLOY POWDER FOR MANUFACTURING OF PROSTHETIC PARTS BY SELECTIVE LASER MELTING
PublicationThe 3D printing is a manufacturing technique belonging to the additive methods able to prepare the designed parts for various purposes. The present reasearch was aimed to fabricate the prosthetic foundations and bridges made of the new Ti-13Zr-13Nb alloy by the selective laser melting (SLM) of a metal powder. The scanning electron examinations and micro scanning tomography were used to investigate the surface quality and intrinsic...
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Selective Laser Melting of Ti Alloy for Manufacturing The Prosthetic Elements
PublicationThe selective laser melting (SLM) is the additive manufacturing method of custom-designed parts. The used materials and the applications are various, including medicine. The titanium and its alloys are materials for which the dimensional quality, surface smoothness and no or extremely low porosity are difficult to reach. In this paper, the successful attempt to obtain by SLM the individually designed prosthetic bridges is described....
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Applications of Additively Manufactured Tools in Abrasive Machining—A Literature Review
PublicationHigh requirements imposed by the competitive industrial environment determine the development directions of applied manufacturing methods. 3D printing technology, also known as additive manufacturing (AM), currently being one of the most dynamically developing production methods, is increasingly used in many different areas of industry. Nowadays, apart from the possibility of making prototypes of future products, AM is also used...
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A Multi Rig Screening Test for Thin Ceramic Coatings in Bio - Tribological Applications
PublicationA method is presented for the comparative testing of wear resistance of ceramic coatings made from materials potentially feasible in tribo - medical applications, mainly orthopaedic implants made from ceramics coated metals for low cost, long life and low wear particle emission into the body. The method was devised as the main tool for use in research and is comprised of flat on flat and ball on flat surface (sliding) tests. Seven...
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Cyclic behaviour modelling of additively manufactured Ti-6Al-4V lattice structures
PublicationThe present work is concerned with the numerical modelling of the cyclic behaviour of Ti-6Al-4V lattice structures. In the study, diamond structures of titanium alloy produced by the additive laser powder bed fusion (LPBF) method with different degrees of relative density were used. Realistic geometric models of the studied mesostructures were generated using computed microtomography, taking into account the imperfections of the...
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Diffusible Hydrogen Control in Flux Cored Arc Welding Process
PublicationOne of the types of hydrogen degradation of steel welded joints is cold cracking. The direct cause of the formation of cold cracks is simultaneous presence of hydrogen, residual stresses and brittle structure. The way of preventing the occurring of degradation is to eliminate at least one of these factors. Practice has shown that the best solution is to control the amount of hydrogen in deposited metal. In this paper an experimental...
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Cooperative control in production and logistics
PublicationClassical applications of control engineering and information and communication technology (ICT) in production and logistics are often done in a rigid, centralized and hierarchical way. These inflexible approaches are typically not able to cope with the complexities of the manufacturing environment, such as the instabilities, uncertainties and abrupt changes caused by internal and external disturbances, or a large number and variety...
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A Circular Waveguide Dual-Mode Filter With Improved Out-of-Band Performance for Satellite Communication Systems
PublicationThis letter presents a novel design for a 3-D-printed circular waveguide dual-mode (CWDM) filter with a modified cavity shape. The modification leads to a wide spurious-free stopband, which is highly desirable for channel separation in waveguide contiguous output multiplexers (OMUXs) in satellite communication systems. The new resonant cavity design is a result of applying shape deformation to a basic circular cavity in order to...
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Biomimetic torene shells
PublicationThe genome inside the eukaryotic cells is guarded by a unique shell structure, called the nuclear envelope (NE), made of lipid membranes. This structure has an ultra torus topology with thousands of torus-shaped holes that imparts the structure a high flexural stiffness. Inspired from this biological design, here we present a novel ‘‘torene’’ architecture to design lightweight shell structures with ultra-stiffness for engineering...
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Three-Dimensional Printing of Bone Models
PublicationThe trabecular bone occurs, for example, in the femoral heads. Understanding the phenomenon of bone tissue degeneration can be the basis for the possibility of looking for alternative methods of surgical treatment of bone loss. The paper presents the results of the trabecular bone model, which was produced in additive manufacturing method with fused filament fabrication technology. The verification of the mechanical behavior of...
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The Smith-Watson-Topper parameter and fracture surface topography relationship for additively manufactured 18Ni300 steel subjected to uniaxial variable-amplitude loading
PublicationIn this paper, the association between Smith-Watson-Topper (SWT) parameter and fracture surface topography is studied in additively manufactured maraging steel exposed to variable-amplitude fatigue loading. The post-failure fracture surfaces were examined using a non-contact 3D surface topography measuring system and the entire fracture surface method. The focal point is on the correspondence between fatigue characteristics, articulate...
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Fast Design Optimization of Waveguide Filters Applying Shape Deformation Techniques
PublicationThis paper presents an efficient design of microwave filters by means of geometry optimization using shape deformation techniques. This design procedure allows for modelling complex 3D geometries which can be fabricated by additive manufacturing (AM). Shape deforming operations are based on radial basis function (RBF) interpolation and are integrated into an electromagnetic field simulator based on the 3D finiteelement method (FEM)....
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Damage detection in 3D printed plates using ultrasonic wave propagation supported with weighted root mean square calculation and wavefield curvature imaging
Publication3D printing (additive manufacturing, AM) is a promising approach to producing light and strong structures with many successful applications, e.g., in dentistry and orthopaedics. Many types of filaments differing in mechanical properties can be used to produce 3D printed structures, including polymers, metals or ceramics. Due to the simplicity of the manufacturing process, biodegradable polymers are widely used, e.g., polylactide (polylactide...
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Studying the Effect of Working Conditions on WEDM Machining Performance of Super Alloy Inconel 617
PublicationWire electrical discharge machining (WEDM) has been for many years a precise and efficient non-conventional manufacturing solution in various industrial applications, mostly involving the use of hard-to machine materials like, among other, the Inconel super alloys. The focus of the present study is on exploring the effect of selected control parameters, including pulse duration, pulse-off time and the dielectric flow pressure on...
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Selected Aspects of 3D Printing for Emergency Replacement of Structural Elements
PublicationThe paper presents a synthetic characterization of modern methods of manufacturing or regenerating machine elements. Considered methods are machining and additive methods, in particular 3D printing in the FDM/FFF technique. For the study, the authors made samples of the holder bracket using selected methods. Samples made by machining operations, 3D printing with various filling were tested. The paper contains a technical and economic...
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Design of a Cellular Dual-Band Sticker Antenna for Thickness-Independent 3D-Printed Substrates
PublicationAdditive manufacturing technology provides high flexibility in designing custom enclosures for prototype devices such as nodes of distributed sensor networks. Although integration of components is desired from the perspective of sensor mobility, it might negatively affect the performance of radio-connectivity due to couplings between the antenna and system peripherals, as well as other unaccounted effects of the 3D printed enclosure....
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Effect of hybrid modification by ceramic layer formation in MAO process and laser remelting on the structure of titanium bio-alloy Ti13Nb13Zr
PublicationTo improve the biological properties of titanium alloy Ti13Nb13Zr, hybrid modifications involving micro-arc oxidation (MAO) and Nd: YAG laser remelting were carried out in two combinations. The first consisted of laser modification before the production of the ceramic layer by the micro-arc oxidation process, and the second combination involved Nd: YAG laser modification after the MAO process. The creation of developed surface...
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A brief note on entire fracture surface topography parameters for 18Ni300 maraging steel produced by LB-PBF after LCF
PublicationThe concept of entire fracture surface investigation is helpful in explaining fatigue phenomena. In this paper, this method has been applied for 18Ni300 maraging steel using a 3D measurement system. Before post-mortem analysis, the specimens produced by laser beam powder bed fusion (LB-PBF) were tested under low-cycle fatigue (LCF) for eight strain amplitudes in the interval 0.3% to 1.0%. The attention was placed on the relationship...
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Fabrication and Characterization of Flexible Medical-Grade TPU Filament for Fused Deposition Modeling 3DP Technology
PublicationThe possibility of using additive manufacturing (AM) in the medicine area has created new opportunities in health care. This has contributed to a sharp increase in demand for 3D printers, their systems and materials that are adapted to strict medical requirements. We described herein a medical-grade thermoplastic polyurethane (S-TPU) which was developed and then formed into a filament for Fused Deposition Modeling (FDM) 3D printers...
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Numerical analysis of mechanical properties of an infill structure used in 3D printings
PublicationThe paper presents results of a numerical analysis focused on an identification of mechanical properties of an element created by using Fused Deposition Modelling additive manufacturing technique (FDM). There is presented a description of technology of the 3D printing, numerical model created by using the finite element method (FEM), as well as some problems referred to estimation of the mechanical properties of the printout. The...
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Biomechanical properties of 3D-printed bone models
PublicationBone lesions resulting from large traumas or cancer resections can be successfully treated by directly using synthetic materials or in combination with tissue engineering methods (hybrid). Synthetic or hybrid materials combined with bone tissue’s natural ability for regeneration and biological adaptation to the directions of loading, allow for full recovery of its biological functions. Increasing interest in new production methods...
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Potential of novel atomic emission techniques as a tool for investigation of the possibilities of using industrial waste as additives in construction materials
PublicationNowadays, due to the global ecological crisis and ways to prevent a climate disaster, more and more attention is paid to green techno-logies and green Chemistry, which are part of the so-called “The Green Deal.” The main assumption is the optimization of the processes of producing necessary goods and the implementation of methods of managing postproduction waste in the least environmentally harmful manner. In the presented research,...
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Strain energy density and entire fracture surface parameters relationship for LCF life prediction of additively manufactured 18Ni300 steel
PublicationIn this study, the connection between total strain energy density and fracture surface topography is investigated in additively manufactured maraging steel exposed to low-cycle fatigue loading. The specimens were fabricated using laser beam powder bed fusion (LB-PBF) and examined under fully-reversed strain-controlled setup at strain amplitudes scale from 0.3% to 1.0%. The post-mortem fracture surfaces were explored using a non-contact...
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The Design of Cavity Resonators and Microwave Filters Applying Shape Deformation Techniques
PublicationThis article introduces shape deformation as a new approach to the computer-aided design (CAD) of high-frequency components. We show that geometry deformation opens up new design possibilities and offers additional degrees of freedom in the 3-D modeling of microwave structures. Such design flexibility is highly desirable if the full potential of additive manufacturing (AM) is to be exploited in the fabrication of RF and microwave...
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Multiple Reprocessing of Conductive PLA 3D-Printing Filament: Rheology, Morphology, Thermal and Electrochemical Properties Assessment
PublicationAdditive manufacturing technologies are gaining more and more attention, resulting in the development or modification of 3D printing techniques and dedicated materials. On the other hand, economic and ecological aspects force the industry to develop material recycling strategies. In this work, the multiple reprocessing of a commercially available PLA conductive composite with carbon black filler, dedicated to 3D printing, was investigated....
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Methods for biomaterials printing: A short review and perspective
PublicationPrinting technologies have opened larger windows of innovation and creativity to biomaterials engineers by providing them with the ability to fabricate complex shapes in a reasonable time, cost, and weight. However, there has always been a trouble with function adjusting in printing technologies in view of the multiplicity of materials and apparatus parameters. 3D printing, also known as additive manufacturing, revolutionized biomaterials...
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Field Calibration of Low-Cost Particulate Matter Sensors Using Artificial Neural Networks and Affine Response Correction
PublicationDue to detrimental effects of atmospheric particulate matter (PM), its accurate monitoring is of paramount importance, especially in densely populated urban areas. However, precise measurement of PM levels requires expensive and sophisticated equipment. Although low-cost alternatives are gaining popularity, their reliability is questionable, attributed to sensitivity to environmental conditions, inherent instability, and manufacturing...