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A novel metal AM technique: additive friction stir deposition

13/4/2018

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Schematic of additive friction stir deposition [1]
​Additive friction stir deposition is a novel metal additive manufacturing technology [1]. A low-temperature and low-cost additive process, it enables fast, scalable manufacturing of metal alloys and composites [2-4]. 

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A novel micro-additive manufacturing technique for flexible electronics printing

23/2/2018

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PictureSchematic of the new setup [1] by N. Holt et al.

​​Researchers in the AM3 lab, at the university of Arkansas, have demonstrated the potential for a new low-costs powder bed AM technique for the manufacturing of micro-components made of low-melting temperature (~600C) powders [1]. Unlike Selective Laser Sintering and Selective Laser Melting that employ a laser beam scanned across the powder bed, the new concept, referred to as MAPS for Micro-Array Powder Sintering, employs arrays of micro-heaters as energy sources. This proof-of-concept could increase build speeds and reduce powder waste and running costs.


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Particles characteristics impact on granular media behaviour in powder bed fusion AM

16/2/2018

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Powder bed fusion additive manufacturing promotes material efficiency as a unique selling point. Unfused particles are in effect recyclable after processing operation and reused [link]. Powder characteristics however tend to vary following different stages of the AM process and these variations could affect powder behaviour and final part quality. Specifically, feedstock quality must be tightly controlled due to their influence on powder flow and packing density.
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Spatter formation and denudation in selective laser melting

2/2/2018

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ref[16]
Under high-volume melting, rapid processing conditions, spatter formation seems to be part and parcel of powder-bed laser-based fusion technology. Three types of spatter particles have been identified:
  • Cold powder particles,
  • Hot powder particles;
  • Hot (partly) molten and re-solidified spatter particles.
Depending on the mechanism involved in its creation, each type of particles has specific physical characteristics that can impact powder recyclability and contribute defects to the final products. Two key mechanisms are responsible for spatter formation and powder bed denudation in the vicinity of the laser track. Let’s have a look at these.

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Powder bed AM machines: ask before you buy

8/12/2017

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Pump made by powder bed fusion AM [1]
Have a peek under the hood of your powder bed fusion machine and here’s what you get: infra-red laser(s), powder reservoirs and overflows, a spreading mechanism, some form of atmosphere control in the build chamber and a software handling digital files and controlling the process sequence.

Fundamentally, there are no processing differences between suppliers' offers!  

For the price of a house, or a luxury car, you get a machine that will be responsible for the reputational credibility of your company and the commercial viability of your production. Yet, it rarely comes with a builders’ or after sale guarantee. 
So it’s best to make sure you have all the unbiased facts at hand to invest your cash sensibly.

​In the next 3 articles, we’ll review the points you will want to keep in mind before you invest in AM technology. Hardware, ease of use, maintenance and end-products quality are a few topics you’ll want to discuss in detail with the suppliers. In the first part, let’s have a look at the hardware itself and what you should pay attention to.

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