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1

The Use of Additive Manufacturing for Production of Commercial Airplane Power Plants Components: A Review

Węgrzyn Nicolas

Safety & Defense

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2022

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2

36--45

EN

The purpose of this paper is to provide an overview of the available Additive Manufacturing (AM) technologies widely documented in many scientific papers and to attempt to answer the question of whether this technology could be used in the optimization of geometry for aircraft engine parts. The core research method in this article is based on the analysis of the scientific literature related to Additive Manufacturing gathered over the past two decades. The discussion starts with a review of various technological solutions, including Powder Bed Fusion (PBF), Direct Energy Deposition (DED) or Electron Beam Melting (EBM). The technological schemes of the processes or their differences are shown, as well as the advantages, disadvantages, and development opportunities. The article also attempts to divide AM technologies in terms of the materials used. The purpose of this approach is to simplify technology selection from an engineering point of view. At the end of this article, industrial ‘in-use’ applications in safety orientated aerospace market are overviewed. As a result of the literature analysis, an attempt is made to prove that modern additive technologies could be used to optimize integrated and complex structures like air bleeds in high pressure compressors of airplane powerplants.

2

Przegląd technologii druku 3D do wykonywania prototypów małych maszyn elektrycznych

Mikoś Jan

Napędy i Sterowanie

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2022

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R. 24, nr 3

68--73

PL

Celem artykułu jest przegląd literatury oraz zebranie najważniejszych osiągnięć druku 3D w dziedzinie maszyn elektrycznych. Technologia druku 3D wykorzystywana jako produkcja addytywna (przyrostowa, dodatkowa) w Przemyśle 4.0 może znacznie ułatwić wykonywanie prototypów nowych, skomplikowanych geometrycznie elementów, skrócić czas ich produkcji, dzięki czemu zmniejszą się nakłady finansowe. Druk 3D umożliwia drukowanie dowolnych geometrii zaprojektowanych w środowisku CAD z materiałów o różnych właściwościach mechanicznych, tak jak i elektrycznych czy magnetycznych, których wykonanie konwencjonalnymi metodami zajęłoby znacznie więcej czasu. W technologii druku 3D należy zwrócić szczególną uwagę podczas obróbki końcowej, czy element nie jest nigdzie zdeformowany lub pęknięty. W przemyśle maszyn elektrycznych w wielu aplikacjach wymagane są skomplikowane struktury, których wykonanie na etapie projektowania jest bardzo kosztowne. Technologia druku 3D może przyspieszyć etap wykonywania prototypów specjalnych maszyn elektrycznych przez wydrukowanie modelu rzeczywistego lub pomniejszonego i sprawdzenie jego parametrów z wykonanymi wcześniej analizami.

EN

3D printing technology used as additive manufacturing (incremental, additional) in industry 4.0 can significantly facilitate making new prototypes, which are geometrically complicated, reduce their production time, and can reduce the financial overhead 3D printing technology can print any geometric designs in a CAD environment with materials characterized by different mechanical, electrical or magnetic properties, which performance using standard methods would take much more time. In 3D printing technology, it should be taken into account during finishing that the element is not deformed or cracked anywhere. In the field of electrical machines, many applications require complex structures that are very expensive in conventional process. 3D printing technology can accelerate the stage of making prototypes of electrical machines, by printing a real or reduced model, and perform its parameters with previously performed analyzes.

3

Zastosowanie druku 3D przy produkcji maszyn elektrycznych z wykorzystaniem metody FDM

Mitka Krystian

Maszyny Elektryczne : zeszyty problemowe

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2022

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Nr 1 (127)

215--220

PL

W ostatnich latach technologia produkcji addytywnej (additive manufacturing), zwana powszechnie drukiem 3D, przechodzi dynamiczny rozwój, a zainteresowanie przemysłu tą technologią rośnie, nie tylko jako metody szybkiego prototypowania (rapid prototyping), lecz także jako sposób wykonywania gotowych obiektów. W niniejszym artykule omówiono rodzaje druku 3D, w szczególności metodę Fused Deposition Modelling (FDM), a także przedstawiono zastosowanie technologii druku 3D w kontekście produkcji maszyn elektrycznych.

EN

3D printing technology have been developing rapidly in the last years. The industry is interested in both the production of prototypes and final parts using additive manufacturing. The paper presents 3D printing technologies and materials from which it is possible to print using this technology. In this article are presented the use of 3D printing in the production of electrical machines.

4

In-situ metal matrix composites development for additive manufacturing: a perspective

Essien U. A., Vaudreuil S.

Journal of Achievements in Materials and Manufacturing Engineering

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2022

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Vol. 111, nr 2

78--85

EN

Purpose: This paper presents an overview on some ceramic materials capable of achieving in-situ reinforcements in Al/Al-alloy metal matrix composites (MMCs) during laser processing. It also presents perspective on further exploitation of the in-situ reinforcement capabilities for high quality MMCs feedstock material development. Design/methodology/approach: The approach utilized in writing this paper encompasses the review of relevant literature on additive manufacturing (AM) of MMCs. Findings: It is widely accepted that the in-situ reinforcement approach has proven to be more advantageous than the ex-situ approach. Though there are still some challenges like the formation of detremental phases and the evaporation of low melting temperature elements, the in-situ reinforcement approach can be used to tailor design composite powder feedstock materials for the AM of MMCs. The preprocessing or tailor-designing in-situ metal matrix composite powder before laser melting into desired components holds more promises for metal additive manufacturing. Practical implications: The need for the development of MMCs powder feedstock that can be directly fabricated using suitable AM technique without prior powder processing like blending or mechanical alloying has not yet been addressed Therefore, having a pre-processed in-situ reinforced MMC feedstock powder can encourage easy fabrication of MMC and other advantages of AM technologies powder recycling. Originality/value: The idea explained in this article is relevant to materials development for AM processing of metal matrix composite. This paper has pointed out future trends for MMCs materials feedstock powder development and new ideas for further exploitation of MMCs and AM technologies. The advantages of tailor-designing composite powders other than merely mixing them has been emphasized.

5

Optimal design of Wire-and-Arc Additively Manufactured I-beams for prescribed deflection

Bruggi Matteo, Laghi Vittoria, Trombetti Tomaso

Computer Assisted Methods in Engineering and Science

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2022

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Vol. 29, no. 4

357--378

EN

Alloys fabricated by wire-and-arc additive manufacturing (WAAM) exhibit a peculiar anisotropy in their elastic response. As shown by recent numerical investigations concerning the optimal design of WAAM-produced structural components, the printing direction remarkably affects the stiffness of the optimal layouts, as well as their shape. So far, single-plate specimens have been investigated. In this contribution, the optimal design of WAAM-produced I-beams is addressed assuming that a web plate and two flat flanges are printed and subsequently welded to assemble the structural component. A formulation of displacement-constrained topology optimization is implemented to design minimum weight specimens resorting to a simplified two-dimensional model of the I-beam. Comparisons are provided addressing solutions achieved by performing topology optimization with (i) conventional isotropic stainless steel and with (ii) WAAM-produced orthotropic stainless steel at prescribed printing orientations. Lightweight solutions arise whose specific shape depends on the selected material and the adopted printing direction.

6

Investigating the capability of low-cost FDM printers in producing microfluidic devices

Haouari K.B., Ouardouz M.

Archives of Materials Science and Engineering

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2022

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Vol. 115, nr 1

5--12

EN

Purpose: This paper aims to investigate the possibilities of using 3D printing by fused deposition modelling (FDM) technology for developing micro-fluidic devices by printing a benchmark test part. A low-cost desktop printer is evaluated to compare the minimum possible diameter size, and accuracy in the microchannel body. Design/methodology/approach: The parts were designed using SolidWorks 2016 CAD software and printed using a low-cost desktop FDM printer and Polylactic acid (PLA) filament. Findings: Desktop 3D printers are capable of printing open microchannels with minimum dimensions of 300 μm width and 200 μm depth. Research limitations/implications: Future works should focus on developing new materials and optimizing the process parameters of the FDM technique and evaluating other 3D printing technologies and different printers. Originality/value: The paper shows the possibility of desktop 3D printers in printing microfluidic devices and provides a design of a benchmark part for testing and evaluating printing resolution and accuracy.

7

Przegląd technologii druku 3D jako produkcji dodatkowej (przyrostowa) do wykonywania prototypów małych maszyn elektrycznych

Mikoś Jan

Maszyny Elektryczne : zeszyty problemowe

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2021

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Nr 2 (126)

1--7

PL

Celem artykułu jest przegląd literatury oraz zebranie najważniejszych osiągnięć druku 3D w dziedzinie maszyn elektrycznych. Technologia druku 3D wykorzystywana jako produkcja addytywna (przyrostowa, dodatkowa) w przemyśle 4.0 może znacznie ułatwić wykonywanie prototypów nowych, skomplikowanych geometrycznie elementów, skrócić czas ich produkcji, dzięki czemu zmniejszą się nakłady finansowe. Druk 3D umożliwia drukowanie dowolnych geometrii zaprojektowanych w środowisku CAD z materiałów o różnych właściwościach mechanicznych, tak jak i elektrycznych, czy magnetycznych, których wykonanie konwencjonalnymi metodami zajęłoby znacznie więcej czasu. W technologii druku 3D należy zwrócić szczególną uwagę podczas obróbki końcowej, czy element nie jest nigdzie zdeformowany lub pęknięty. W przemyśle maszyn elektrycznych w wielu aplikacjach wymagane są skomplikowane struktury, których wykonanie na etapie projektowania jest bardzo kosztowne. Technologia druku 3D może przyśpieszyć etap wykonywania prototypów specjalnych maszyn elektrycznych, przez wydrukowanie modelu rzeczywistego lub pomniejszonego i sprawdzenie jego parametrów z wykonanymi wcześniej analizami.

EN

3D printing technology used as additive manufacturing (incremental, additional) in industry 4.0 can significantly facilitate making new prototypes, which are geometrically complicated, reduce their production time, and can reduce the financial overhead 3D printing technology can print any geometric designs in a CAD environment with materials characterized by different mechanical, electrical or magnetic properties, which performance using standard methods would take much more time. In 3D printing technology, it should be taken into account during finishing that the element is not deformed or cracked anywhere. In the field of electrical machines, many applications require complex structures that are very expensive in conventional process. 3D printing technology can accelerate the stage of making prototypes of electrical machines, by printing a real or reduced model, and perform its parameters with previously performed analyzes.

8

A review of fabrication polymer scaffolds for biomedical applications using additive manufacturing techniques

Szymczyk-Ziólkowska Patrycja, Labowska Magdalena Beata, Detyna Jerzy, Michalak Izabela, Gruber Piotr

Biocybernetics and Biomedical Engineering

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2020

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Vol. 40, no. 2

624--638

EN

This paper presents the current state-of-the art of additive manufacturing (AM) applications in the biomedical field, especially in tissue engineering. Multiple advantages of additive manufacturing allow to precise three-dimensional objects fabrication with complex struc-ture using various materials. Depending on the purpose of the manufactured part, different AM technologies are implemented, in which a specific material can be utilized. In the biomedical field, there are used several techniques such as: Binder Jetting, Material Extru-sion, Material Jetting, Powder Bed Fusion, Sheet Lamination, Vat Polymerization. This article focuses on the utilization of polymer materials (natural and synthetic) taking into account hydrogels in scaffolds fabrication. Assessment of polymer scaffolds mechanical properties enables personalized patient care, as well as prevents damage after implantation in human body. By controlling process parameters it is possible to obtain optimised mechanical properties of manufactured parts.

9

A comprehensive study of mechanical and acoustic properties of selective laser melting material

Barile Claudia, Casavola Caterina, Moramarco Vincenzo, Vimalathithan Paramsamy Kannan

Archives of Civil and Mechanical Engineering

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2020

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Vol. 20, no. 1

30--40

EN

In this research work, four groups of selective laser melted specimens were built from AlSi10Mg-0403 powder. Each group represents the direction with respect to the bed in which the specimens are built (X, Y, Z and 45° orientation). The mechanical properties of the specimens are characterized in terms of yield strength, ultimate tensile strength, Young’s modulus and elongation at break. In addition to that, the acoustic emission (AE) during the testing was monitored using wide-band high-accuracy piezoelectric sensors. The AE results were related to the mechanical characteristics of the specimens in terms of the acoustic parameter-based data, the peak amplitude, cumulative energy and count rate. The mechanical results show that the specimens built along the z direction have relatively lower strength and it can be attributed to the borderline porosity formed during the SLM process. The acoustic results can identify the critical points of failure under loading. The AE technique proves to be a powerful tool in characterizing the mechanical property and can unveil the concealed information which cannot be identified directly from the mechanical results.

10

Peculiarities of simulation of the additive process of forming of 3D products from steel 09G2S

Grigorenko G. M., Kostin W. A., Mossokovskaya I. A.

Przegląd Spawalnictwa

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2017

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R. 89, nr 9

42--48

EN

The results of modeling of thermal fields, stresses, deformations and displacements in formation of an additive structure of 09G2S steel on a substrate are presented. An interdisciplinary research computational package COMSOL Multiphysics was used for computer modeling. Effect of the temperature on physicochemical parameters of steel was taken into account in the work. The results for modeling were obtained using Gleeble 3800 a complex for simulation of thermal deformation state of welding thermal cycle. Some physical-thermal properties of 09G2S steel were calculated using JmatPro 6.0 software package. Carried investigation showed that the highest level of residual stresses and deformations in additive deposition of 09G2S steel layers on the substrate is reached at the boundary of the first layer and substrate and makes 280–320 MPa. Stresses between the layers of deposited metal are significantly lower (to 50 MPa). It is determined that the increase of the number of deposited layers provokes nonlinear rise of a level of stress at the additive layer/substrate boundary and does not depend on the number of deposited layers in time. In additive manufacturing process, preheating to at least 300÷320 °C temperature should be used to prevent noticeable deformation of the substrate. Developed software can be used for mathematical modeling of additive process of formation of steel, titanium and aluminum alloys structures.

PL

Przedstawiono wyniki modelowania pól termicznych, naprężeń, odkształceń i przemieszczeń przy formowaniu konstrukcji addytywnej ze stali 09G2S na podkładce. Dla dokonanego modelowania komputerowego wykorzystano pakiet dla międzydyscyplinarnych badań COMSOL Multiphysics. W pracy uwzględniono wpływ temperatury na parametry fizykochemiczne stali. Wyniki dla modelowania otrzymano z wykorzystaniem kompleksu imitowania stanu termo-odkształceniowego cyklu termicznego spawania Gleeble 3800. Właściwości fizyko-termiczne stali 09G2S obliczono za pomocą pakietu JmatPro 6.0. Przeprowadzone badania świadczą, że przy nanoszeniu addytywnym warstw stali 09G2S na podkład największy poziom naprężeń resztkowych i odkształceń osiąga się na granicy pierwszej warstwy i podkładki i stanowi 280÷320 MPa. Naprężenia miedzy warstwami metalu napawanego są znacznie niższe (do 50 MPa). Ustalono, że ze wzrostem ilości warstw naniesionych poziom naprężeń na granice warstwa addytywna/podkład wzrasta nieliniowo i z czasem nie zależy od ilości warstw nanoszonych. Przy procesie addytywnym dla zapobiegania odkształcenia podkładu należy stosować poprzednie nagrzewanie do temperatur 300÷320 °С. Te programy mogą być stosowane dla modelowania matematycznego procesu formowania konstrukcji ze stali i stopów aluminiowych.