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Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

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Controlling grain structure in metallic additive manufacturing using a versatile, inexpensive process control system.

Lova Chechik¹, Alexander D Goodall², Katerina A Christofidou²

¹Department of Materials Science and Engineering, The University of Sheffield, Mappin Street, Sheffield, S1 3JD, UK. lchechik@live.co.uk.

Scientific Reports

|June 20, 2023

Summary

This summary is machine-generated.

A new, affordable process control system for additive manufacturing (AM), or 3D printing, significantly reduces melt pool variability and improves part quality. This advancement enhances consistency in metallic AM processes, aiding certification and broader industrial adoption.

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Area of Science:

Materials Science
Manufacturing Engineering
Process Control

Background:

Additive manufacturing (AM), or 3D printing, offers significant industrial advantages in sectors like aerospace and medicine.
A key challenge in metallic AM is ensuring process consistency for reliable component certification.
Variability in the melt pool during AM can lead to microstructural inconsistencies in final parts.

Purpose of the Study:

To develop and integrate a cost-effective process control system for additive manufacturing.
To reduce variability in melt pool fluctuations during metallic AM.
To improve the microstructural homogeneity and consistency of 3D printed components.

Main Methods:

Development and implementation of a versatile, inexpensive process control system.
Integration of the system to monitor and manage melt pool dynamics.
Analysis of microstructural variations in relation to geometric changes and heat flow.

Main Results:

Achieved up to a 94% reduction in grain area variability.
Successfully reduced melt pool fluctuation, leading to improved microstructural homogeneity.
Developed in-house control software, made publicly available to lower implementation barriers.

Conclusions:

The developed process control system offers a significant, cost-effective solution for enhancing consistency in metallic AM.
Understanding heat flow mechanisms related to geometry is crucial for further optimization.
The system's accessibility and effectiveness promote wider adoption of feedback control in various manufacturing processes, including polymer AM and injection molding.