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Experimental Procedure for Warm Spinning of Cast Aluminum Components

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Evaluation of a High-Temperature Pre-Heating System Design for a Large-Scale Additive Manufacturing System.

Rabelani Duncan Ramulifho¹, Kapil Gupta¹, Daniel Glaser²

¹Department of Mechanical and Industrial Engineering Technology, University of Johannesburg, Johannesburg 2028, South Africa.

|September 23, 2022

Summary

This summary is machine-generated.

Inefficient preheating in large-scale Additive Manufacturing (AM) using Selective Laser Melting (SLM) causes heat loss. Redesigning the system with better insulation and component configuration can achieve higher substrate temperatures for improved performance.

Keywords:

additive manufacturing high-temperature insulation residual stress selective laser melting thermal analysis

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Area of Science:

Materials Science
Manufacturing Engineering
Thermal Engineering

Background:

Additive Manufacturing (AM) of titanium (Ti6Al4V) via Selective Laser Melting (SLM) can lead to tensile residual stresses and premature component failure.
Large-volume AM machines like Aeroswift utilize high-temperature substrate preheating to mitigate thermal gradients.
The current Aeroswift platform's preheating system is unable to reach the target build-plate temperature of 600 °C.

Purpose of the Study:

Analyze the inefficiency of the current preheating system design.
Identify the causes of heat loss and suboptimal performance.
Propose and evaluate design improvements for enhanced preheating capabilities.

Main Methods:

Finite Element Analysis (FEA) to model thermal performance of the heating system.
Experimental testing of heater and insulation materials.
Analysis of heat loss due to component contact and inadequate insulation.

Main Results:

FEA revealed the ceramic heater reached 395 °C and substrates reached 374 °C.
Inadequate insulation and metal component contact caused significant heat loss.
Experimental tests showed 44% insulation efficiency and a maximum plate temperature of 548.8 °C.

Conclusions:

The current preheating system's design is inefficient due to heat loss mechanisms.
Improved insulation and component configuration in a new design can achieve 650 °C.
Optimizing large-scale preheating systems is crucial for improving AM performance and component integrity.