There are different types of Metal Additive Manufacturing technologies, here are the most important.
Directed Energy Deposition (DED):
It is composed by a head from where a laser, or a electron or a plasma ray exits. On the head, a pressurized system is installed, from where metal powder is ejected in a way that hits the ray and melting occurs. Both the head and component can move. It is possible to use, instead of powder, a filament, cheaper but that gives lower quality.
Turn up the volume!
https://www.youtube.com/watch?v=oL7bMhPTtDI
Powder Bed Fusion:
A powder bed is deposited and material is melted only where necessary. Once the material is melted, another layer of powder is deposited, and so on.
Depending on the energy source, we speak of:
1. Selective Laser Melting (SLM):
The source is a laser and the working chamber is filled with inert gas, to avoid combustion or explosions. The head moves, the component is fixed. Selective Laser Sintering (SLS) is similar, but the material is not really melted, is sinterized (lower temperatures).
Maximum obtainable dimensions are (600x400x500) mm^3.
https://www.youtube.com/watch?v=te9OaSZ0kf8
2. Electron Beam Melting (EBM):
The source is an electron gun. It is composed by a cathode made of tungsten that is heated until it reaches temperature higher than 2000 °C, (melting point of tungsten is about 3400 °C, this is why tungsten is used) emitting electrons than are accelerated through the application of a voltage (V or Volt) between the same cathode and an anode collocated below.
In this way, an electron beam is emitted, that is focused through a repulsive disk (a magnet) and reaches the material, melting it.
The electron beam can be oriented through a magnetic field, removing any moving part and so, any friction. This makes this technology faster but also more expensive (not less than 1 million euros).
The chamber has to be taken under vacuum and at a temperature of 1000 °C. Working at these temperature reduces thermal stresses.
Maximum obtainable dimensions are (350x350x380) mm^3.
https://www.youtube.com/watch?v=CUeDevI6kyE
The main parameters that infleunce the quality of a component obtained with Additive Manufacturing are:
Energy density: we have to set the right power of the source, the right speed, the right distance, avoiding material vaporization or chemical composition changes (too much energy) or lack of fusion (too low energy). The quality of the component is measured comparing the final mass with the expected from theory one: in fact, generally speaking, components obtained with AM have a lower density than ones obtained through CNC technologies, because of the higher air inclusions. This results in lower mechanical porperties;
Powder: chemical composition, dimensions (we can reach nanometers), morphology, physical properties, storaging, reutilizability and dangerousness. Aluminum powder cost is 30 €/Kg, Steel 70 €/kg, Titanium 150 €/Kg, NiTiNOL 700 €/Kg (approximate values);
Deposition strategy: it influences material orientation, resulting in a material anisotropy (different mechanical properties in different directions). In conclusion, it influences the mechanical properties of the component;
Rugosity; we obtain higher rugosity than in traditional technologies (CNC). Surface post processing is necessary.
Metal Additive Manufacturing is a competitive technology, considering time and costs, only for low numbers of components, with very complex geometries that are not obtainable with other technologies.
For big lots and simpler geometry, CNC technologies are still the best choice.
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